nuda 900 2012 nuda 900 r 2012

NUDA 900 2012NUDA 900 R 2012

Workshop Manual Ed. 11-2011

HUSQVARNA MOTORCYCLES S.R.L. - Varese disclaims all liabilities for any errors or omissions in this manual and reserves the right to make changes to reflect on-going product development. Illustrations in the ma-nual may differ from actual components. No reproduction in full or in part without written authorisation.1st edition (11-2011)

a.1

simbo

lo

NUDA 900 2012 - NUDA 900 R 2012

NUDA 900: ZKHA700A#CV000001NUDA 900 R: ZKHA700B#CV000001

NUDA 900 2012NUDA 900 R 2012


FOREWORD, TABLE OF CONTENTS

1st edition (11-2011)Printed in Italy

MODELS COVERED (from serial number onwards)

Copyright byHUSQVARNA MOTORCYCLES S.R.L.BMW GroupTechnical ServiceVia Nino Bixio, 821024(Varese) - Italytel. ++39 0332 75.61.11tel. ++39 0332 756 558www.husqvarna-motorcycles.com

Workshop Manual

1. Chassis serial number

a.2

simbo

lo

NUDA 900 2012 - NUDA 900 R 2012



ForewordThis publication is designed for use by HUSQVARNA Service Centres to assist authorised personnel in the maintenance and repair of the models covered in this manual. The technical information provided in this manual is a critical comple-ment to operator training and operators should become thoroughly familiar with it.

This publication is for the exclusive use of those HUSQVARNA technicians who have an adequate basic mechanical preparation and a good knowledge of the vehicles repair procedures. Thus much information has been intentionally omitted as it was considered superfluous. The technicians must adopt special safety procedures that they will deem necessary in order to prevent damages to the motorbike, to its components, and to people.

For ease of understanding, diagrams and photographs are provided next to the text.Notes with special significance are identified as follows throughout the manual:

Accident-prevention rules for operator and persons working nearby.

Damage to vehicle and/or its components may result from incompliance with relevant instructions.

Additional information concerning the operation covered in the text.

Useful tipsTo prevent problems and ensure effective service work, observe the following HUSQVARNA recommendations:– before repair, evaluate the customer's description of the problem and ask the appropriate questions to clearly identify

problem symptoms;– diagnose the problem and identify the causes clearly. This manual provides basic background information that must

be supplemented with the operator's expertise and specific training available through HUSQVARNA held at regular periods;

– plan ahead before starting work: gather any spare parts and tools to avoid unnecessary delays;– avoid unnecessary disassembly work to get to the part that needs repairing. Always read the relevant instructions and follow the disassembly sequence outlined in this manual.

a.3

simbo

lo

NUDA 900 2012 - NUDA 900 R 2012



NOTES

Unless otherwise specified, data and specifications apply to all models.

Table of ContentsTitle SectionForeword, Table of Contents ...............................................................................aImportant Notices ................................................................................................bGeneral Information .............................................................................................AMaintenance ........................................................................................................BTroubleshooting .................................................................................................. CSettings and Adjustments ................................................................................... DGeneral Procedures ............................................................................................EEgine settings and adjustments...........................................................................FGeneral engine procedures ...............................................................................F1Cylinder head removal/disassembly ..................................................................F2Crankcase disassembly.....................................................................................F3Engine torque figures ........................................................................................F4Wear limits of engine parts ................................................................................F5Front Suspension ................................................................................................. IRear Suspension ................................................................................................. JBrakes ................................................................................................................. LElectrical System ................................................................................................MEngine Cooling ................................................................................................... NTightening Torque Figures ...................................................................................XChassis and Wheels ............................................................................................Y

b.1

NUDA 900 2012 - NUDA 900 R 2012

b


IMPORTANT NOTICES

Section

b.2

NUDA 900 2012 - NUDA 900 R 2012

IMPORTANT NOTICES


GENERAL SAFETY WARNINGSRead these general recommendations carefully before using the vehicle.

Carbon monoxideOnly run the engine in an open or very well ventilated area. If you do work in an enclosed area, make sure you use a fume extraction system.

Exhaust emissions contain carbon monoxide, a poisonous gas which can cause loss of consciousness and even death if inhaled.

Parts of the vehicle that become hotBefore working on the engine and the exhaust unit, wait for them to cool down; while the vehicle is running, these parts become very hot and remain hot for some time after turning off the engine.

Risk of burns - work with caution and wear suitable PPE if necessary.

Fuel The fuel used to power internal combustion engines is highly flammable and explosive.

Do all fuelling and maintenance operations with the engine switched off and in ventilated areas; do not smoke and avoid contact between the fuel and naked flames, sparks, etc. that may cause an explosion.

Do not dispose of fuel in the environment.

Keep out of reach of children.

Do not tilt the vehicle excessively since this may cause fuel to leak.

EngineIn some cases, coolant may become inflammable and if burnt, produce invisible flames which cause burns.

Do not spill coolant onto hot components like the engine or exhaust pipe, etc. since it may ignite. During maintenance work, wear latex gloves. Never leave the coolant in open containers in areas accessible to children and animals since it is toxic.

DO NOT remove the radiator cap when the engine is hot; the coolant is pressurised and may cause scalding.

Engine oil Do not dispose of oil in the environment since it is highly polluting.

Keep out of reach of children. Wear latex gloves since prolonged contact with the skin can cause serious damage. Send used oil to special authorised recyclers in accordance with the legal requirements in force in the country where

the vehicle will be used.

Brake fluid Brake fluid is highly corrosive and may damage the rubber and painted parts of the vehicle.

While performing maintenance work, protect your eyes by wearing special goggles and wear protective gloves. In the event of accidental contact with the eyes, rinse them with plenty of clean, running water and seek medical advice

immediately.


b.3

NUDA 900 2012 - NUDA 900 R 2012

H10571

1

2


IMPORTANT NOTICES

Battery Recharge the battery in well ventilated areas since the battery produces toxic, highly inflammable gases when being recharged; do not smoke or use naked flames or sparks.

The liquid in the battery is highly corrosive. If it comes into contact with the skin, rinse thoroughly with running water. It is extremely important to protect your eyes because even a small amount of liquid can cause irreversible damage to the eyes.

If it comes into contact with the eyes, rinse thoroughly with clean, running water and if swallowed accidentally, drink

plenty of water or milk. In all cases, seek medical advice immediately.

The battery liquid is corrosive and should not be poured onto the painted or rubber parts.

The battery liquid is highly polluting. DO NOT dispose in the environment; at the end of its service life, take the battery to the special authorised recycling centres in accordance with the legal requirements in force in the country where the vehicle will be used.


NUDA 900 and NUDA 900 R models are STREET LEGAL motorcycles; they are guaranteed exempt from functional defects and covered with legal guarantee, as far as the STANDARD CONFIGURATION IS MAINTAINED and the suggested maintenance table shown in Section "B" is observed.

* In order to maintain the vehicle’s “Guarantee of Functionality”, the client must follow the maintenance programme indicated in Section B by having the required maintenance inspections carried out at authorised HUSQVARNA dealers. The cost for changing parts and for the labour necessary in order to comply with the maintenance plan is charged to the Client. The warranty becomes NULL AND VOID if the motorcycle is rented.

NotesLeft and right side is determined when seated on motorcycle.

Z: number of teeth

A: AustriaAUS: AustraliaB: BelgiumBR: BrazilCDN: CanadaCH: SwitzerlandD: GermanyE: SpainF: FranceFIN: FinlandGB: Great BritainI: ItalyJ: JapanUSA: United States of America

Unless otherwise specified, data and instructions apply to all market variants.

b.4

NUDA 900 2012 - NUDA 900 R 2012

IMPORTANT NOTICES


RECOMMENDED SHOP PRACTICESBefore disassembling components or before performing repair operations, clean the motorbike removing possible mud, dust, or foreign bodies.

- Put the vehicle in a well lit area;- Fasten the vehicle in a steady position so that it cannot overturn; use suitable stands and belts.- Use suitable equipment for lifting/removing heavy parts.- Use appropriate keys (not pliers) to loosen/tighten nuts and screws.- When loosening or tightening nuts or bolts, always begin with the bigger ones or from the centre. Tighten to the specified torque

and follow a cross pattern or a dedicated pattern as outlined in the relevant section.- Always mark any parts or positions that might be confused upon assembly.- Use special tools where specified.- Clean thoroughly the removed components before refitting them- During the reassembly, make sure that the bearings turn freely without obstruction or without getting stuck, otherwise replace

them- Always replace the seals, the sealing rings, the split pins, the screws with damaged thread, and the self-locking nuts with new

parts.- Use genuine HUSQVARNA parts and the recommended lubricant brands.- At the end of a repair or periodic maintenance, test the vehicle before delivering it to the customer.

Electrical parts- Disconnect the electrical component connectors by pressing the special safety hooks.- Make sure that inside the connector there is no dirt or rust; if need be, clean them with an air jet or suitable products.- Make sure that the cables are correctly seamed to the connector terminals.- When you reconnect the connectors, ensure the correct coupling.

Do not disconnect the connectors by pulling the electrical cables.

- Technical Bulletins might contain more up-to-date setting data and procedures than this manual. Be sure to read them.

Where not specified, refit the previously removed components following the procedures in the reverse order with respect to the removal.

A.1

NUDA 900 2012 - NUDA 900 R 2012

A


GENERAL INFORMATION

Section

A.2

NUDA 900 2012 - NUDA 900 R 2012

GENERAL INFORMATION


Engine ..........................................................................................................A.3Timing system ..............................................................................................A.3Lubrication ....................................................................................................A.3Ignition ..........................................................................................................A.3Fuel system ..................................................................................................A.3Primary drive ................................................................................................A.3Clutch ...........................................................................................................A.3Transmission ................................................................................................A.3Secondary drive............................................................................................A.4FINAL RATIOS .............................................................................................A.4Chassis .........................................................................................................A.4Front suspension ..........................................................................................A.4Rear suspension...........................................................................................A.4Front brake ...................................................................................................A.4Rear brake ....................................................................................................A.5Rims .............................................................................................................A.5Tyres .............................................................................................................A.5Weight, capacity ...........................................................................................A.5Table for lubrication, supplies .......................................................................A.5Electrical components location .....................................................................A.6Dimension.....................................................................................................A.7

A.3

NUDA 900 2012 - NUDA 900 R 2012


GENERAL INFORMATION

EngineType ....................... inline twin cylinder, 4 stroke, with four valves per cylinderCooling ............................................................................. liquid and electric fan

Bore ......................................................................................... 3,31 in. (84 mm)Stroke ...................................................................................... 3,19 in. (81 mm)Displacement ........................................................................ 54,8 in3 (898 cm3)Compression ratio ......................................................................................13:1

Starting .................................................................................................. electricType of fuel ............................................................. unleaded fuel 95ROZ/RON

Timing systemtype ................................................ double overhead camshaft chain operated; 4 valves per cylinder

Valve clearance (with engine cold)Intake .........................................................0,0091 ÷ 0,013 in. (0.23 ÷ 0.33 mm)Exhaust...................................................0,0118 ÷ 0,0161 in. (0.30 ÷ 0.41 mm)

Lubricationtype ........................................................... dry sump oil circuit with built-in tank, cartridge filter and oil/water heat exchanger

Ignitiontype .....................................Electronic with adjustable advance (digital control)Spark plug type......................................................................“NGK” LMAR8C-9Spark plug electrode gap ...........................0,0315 ÷ 0,0354 in. (0.8 ÷ 0.9 mm)

Fuel systemtype ...............................................................................Electronic injection feed

Primary driveDrive gear on crankshaft ............................................................................ Z 35Driven gear on clutch housing .................................................................... Z 68Transmission ratio ....................................................................................1.943

Clutchtype ..........................................oil bath multiple disc clutch, mechanical control

Transmissiontype ............................................................................. constant mesh gear type

Transmission ratio1st gear......................................................................................... 2.462 (32/13)2nd gear ....................................................................................... 1.750 (28/16)3rd gear ........................................................................................ 1.381 (29/21)4th gear ........................................................................................ 1.174 (27/23)5th gear ........................................................................................ 1.042 (25/24)6th gear ........................................................................................ 0.960 (24/25)

A.4

NUDA 900 2012 - NUDA 900 R 2012

GENERAL INFORMATION


Secondary drivetransmission sprocket (NUDA 900) ........................................................... Z 17Transmission sprocket (NUDA 900 R) ........................................................ Z 16Rear wheel sprocket ................................................................................... Z 42Transmission ratio (NUDA 900) ...................................................................2.47Transmission ratio (NUDA 900 R) .............................................................2.625Transmission chain dimensions ............................................. 5/8” x 5/16” (525)

FINAL RATIOSNUDA 9001st gear....................................................................................................11,8152nd gear ....................................................................................................8,3983rd gear .....................................................................................................6,6274th gear .....................................................................................................5,6345th gear .....................................................................................................5,0006th gear .....................................................................................................4,607

NUDA 900 R1st gear....................................................................................................12,5572nd gear ....................................................................................................8,9253rd gear .....................................................................................................7,0434th gear .....................................................................................................5,9875th gear .....................................................................................................5,3146th gear .....................................................................................................4,896

Chassistype ............................... tubular steel trellis with removable steel rear chassis.

Front suspensionNUDA 900Type upside-down hydraulic fork ...................................1,89 in. (ø 48 mm) legsWheel travel........................................................................... 8,27 in. (210 mm)

NUDA 900 RType upside-down hydraulic fork (adjustable compression, rebound and spring reload) ....................................... ø 1,89 in. (ø 48 mm) legsWheel travel........................................................................... 8,27 in. (210 mm)

Rear suspensionNUDA 900Type .................................................................direct with hydraulic monoshock (adjustable spring preload and hydraulic rebound damping)Wheel travel........................................................................... 7,09 in. (180 mm)

NUDA 900 RType .................................................................direct with hydraulic monoshock (adjustable spring preload and hydraulic compression and rebound damping; adjustable length)Wheel travel........................................................................... 7,09 in. (180 mm)

Front brakeType .....................................................twin floating disc ø 12,6 in. (ø 320 mm) with radial pump and radial callipers

A.5

NUDA 900 2012 - NUDA 900 R 2012


GENERAL INFORMATION

Rear brakeType ............................... fixed disc ø 10,43 in. (ø 265 mm) and floating calliper

RimsFront .................................................................................in light alloy: 3.5”x17”Rear ..................................................................................in light alloy: 5.5”x17”

TyresFront ............................................................................................120/70xZR17”Rear .............................................................................................180/55xZR17”

Cold tyre pressureFront ................................................................................32,71 psi (2.3 kg/cm2)Rear .................................................................................35,55 psi (2.5 kg/cm2)

Weight, capacityKerb weight, without fuel. ......................................................407,85 lb (185 kg)Dry weight...............................................................................383,6 lb. (174 kg)Fuel tank capacity reserve included ........................................... 2,86 Imp. Gall 3,43 U.S. Gall. / 13 lFuel reserve................................................................... approx. 0,66 Imp. Gall. approx. 0,79 U.S. Gall. approx. 3 lCoolant tank capacity ................................................................. 0,31 Imp. Gall. 0,37 U.S. Gall. 1.4 lTransmission oilOil and oil filter replacement ....................................................... 0,73 imp. Gall. 0,87 U.S. Gall. 3.3 lOil replacement ............................................................................ 0,7 Imp. Gall. 0,85 U.S. Gall. 3.2 lOil top up between minimum and maximum level ....................... 0,09 Imp. Gall 0,11 U.S. Gall. 0.4 l

Table for lubrication, suppliesEngine, gearbox and primary drive lubricating oil 1) CASTROL POWER1 RACING SAE 5W-40 2) SAE rating: 15W-40 API: SG/SH JASO: MAEngine coolant ..................................... CASTROL MOTORCYCLE COOLANTBrake fluid ...........................................CASTROL RESPONSE SUPER DOT 4 Grease lubrication ....................................................CASTROL LM GREASE 2Secondary drive chain lubrication................ CASTROL CHAIN LUBE RACINGFront fork oil.............................................................TITAN SAF 1091 (FUCHS)Rear shock absorber oil............................ SYNTHETIC FORK OIL SAF 1091 *Electric contact protection ......................CASTROL METAL PARTS CLEANER

* NOTE: Only an authorised Ohlins centre can service the rear shock absorber of the R version.

A.6

NUDA 900 2012 - NUDA 900 R 2012

GENERAL INFORMATION


Electrical components locationThe ignition system includes the following elements:- Generator on the inner side of R.H. crankcase half cover;- Electronic ignition coil with integrated spark plug cap positioned on cylinder head;- Electronic control unit on the front part in front of the filter box;- Spark plugs on the cylinder heads;- Starter motor in front of the cylinders@ block;- Solenoid starter on the central part behind the battery;- Potentiometer on throttle body;- Voltage regulator on a support on the battery. - Crankshaft position sensor on the right-hand side of the engine.

The electrical system includes the following elements:- 12V - 12Ah battery in the central part;- Turning indicator flasher integrated in the digital instrument;- Relay for fuel pump, general relay and fan positioned on the front part in front of the control unit;- Electric fan;- Secondary fuses positioned on the rear part under the saddle; two 30A main fuses on the solenoid starter;- Coolant temperature sensor on the cylinder head;- Lambda sensor;- Headlamp with H4-12V-55/60W halogen bulb and 12V-5W parking light bulb;- LED tail light with stop light bulb;- 12V-6W turning indicator bulbs;- Fuel pump inside the tank.- Multifunction digital instrument.

A.7

NUDA 900 2012 - NUDA 900 R 2012

H10575

1495 mm

2190 mm

893

mm

A

195 mm

1220

mm

2

3


GENERAL INFORMATION

DimensionWheelbase ........................................................................ 58,86 in. (1495 mm)Overall length .................................................................... 86,22 in. (2190 mm)Overall width ....................................................................... 35,16 in. (893 mm)Max. height ........................................................................ 48,03 in. (1220 mm)A= Seat height (NUDA 900) ............................................... 34,25 in. (870 mm)A= Seat height (NUDA 900 R) ......................34,45 ÷ 35,04 in. (mm 875 ÷ 890)Min. ground clearance ........................................................... 7,68 in. (195 mm)

B.1

NUDA 900 2012 - NUDA 900 R 2012

B


MAINTENANCE

Section

B.2

NUDA 900 2012 - NUDA 900 R 2012

MAINTENANCE


NUDA 900 / NUDA 900 R SCHEDULED MAINTENANCE CHART (TO BE CARRIED OUT AT THE HUSQVARNA DEALER)

ENGINESERVICE COUPON

SERVICE COUPON

SERVICE COUPON

SERVICE COUPON

SERVICE COUPON

After the first

1.000 Km

EVERY 10.000 Km

EVERY 20.000 Km

EVERY 30.000 Km

EVERY 40.000 Km

Check engine oil level X X X X X EVERY 1.000 Km

Replace engine oil together with oil filter, clean magnetic plug M24x2

X X X X X

EVERY 10.000 Km

or ONCE A YEAR

Check / adjust valve play X X EVERY 20.000 Km

Replace spark plugs X X EVERY 20.000 Km

Check coolant level X EVERY 1.000 Km

Replace coolant

X X

EVERY 20.000 Km

or EVERY 2 YEARS

Check / adjust clutch play X X X X X EVERY 1.000 Km

B.3

NUDA 900 2012 - NUDA 900 R 2012


MAINTENANCE

NUDA 900 / NUDA 900 R SCHEDULED MAINTENANCE CHART (TO BE CARRIED OUT AT THE HUSQVARNA DEALER)

CHASSISCHECKS SERVICE

COUPONSERVICE COUPON

SERVICE COUPON

SERVICE COUPON

SERVICE COUPON

EVERY 1.000 Km

After the first

1.000 Km

EVERY 10.000 Km

EVERY 20.000 Km

EVERY 30.000 Km

EVERY 40.000 Km

Check and lubricate secondary chain Lubricate the secondary drive chain at least once every 1,000 km. If used on dusty or wet roads, do this more frequently

Check front/rear sprockets for wear: if ne-cessary, replace along with the secondary drive chain

X X X X X X

Air filter X X R X R

Second.Drive chain: check tension and wear (1) X, L X, L X, L X, L X, L X, L

Transmission cables and controls X X XSteering bearings and steering clearance X X XWheel bearings X XControl unit diagnosis X X X X XBrake discs X X X X X XFront fork X XRear shcok absorber X XGeneral vehicle operation X X XCooling system X X XBraking systems X X XLights X X XSafety switches X X X X XBrake fluid (2) X X X X X XCoolant (2) X X X X X XLight alignmentCush drive dampers X XTyres: pressure / wear X X X X X XWheels X X X XOverall tightening of nuts and bolts X X XSide stand X L L L L LSuspension and alignment X X XFuel hoses (3) XBrake pad wear X X X X X XCheck cooling-water tubes and water pump for condition and leakage / replace if necessary

X X X X

X: Inspect and clean, adjust, lubricate or replace if necessary.R: Change.L: Lubricate.(1): Check and clean, adjust or replace if necessary every 1,000 km. (2): Replace every 2 years.(3): Replace every 4 years.

C.1

NUDA 900 2012 - NUDA 900 R 2012

C

Manuale d'officina Ed. 11-2011

TROUBLESHOOTING

Section

C.2

NUDA 900 2012 - NUDA 900 R 2012

TROUBLESHOOTING


ENGINE

Trouble Possible causes Remedy

Starter motor does not operate or does not turn engine over

Ignition switch not in ON position Switch ignition switch to position ONEngine-stop-switch on OFF position Switch to position ONDischarged battery, loose or corroded connections

Check/replace battery and check connec-tions, check charging system

Ignition circuit in short-circuit Check ignition circuitStarter motor defect Replace starter motor

Engine turns over but does not start engine or starts hard

Spark plugs loose Tighten spark plugsSpark plugs not according to specifications or defective Replace spark plug

Spark plugs fouled or wet Clean or exchange

Battery nearly discharged, starting rpm too low

Check/replace battery and check con-nections, check if battery is charged by generator

Fuel supply inadequate

Check fuel tank if emptyCheck / replace fuel filter, fuel supply pi-pes, fuel pump, fuel pressure sensor and injectors

Valve clearance below specification Adjust valve clearance according to spe-cification

Valve timing incorrect Adjust position of camshaft gearsIgnition coil or ignition cable defective Check / replaceIgnition unit defective, ignition timing in-correct

Check / replace crank position trigger and ECU

Cylinder gasket defective Exchange cylinder head gasketValves and valve guides worn or imperfect valve seat

Exchange valves, rework valve seats or exchange cylinder head

Piston rings and/or cylinder bore worn Exchange piston rings and/or cylinderEngine oil too heavy (winter operation) Exchange engine oil

Engine runs irregularly at idle

Excessive spark plug electrode gap Exchange spark plug

Valve clearance below specification Adjust valve clearance according to spe-cification

Intake socket not tight or leaking Tighten intake socket or exchange if ne-cessary

Ignition unit defective, ignition timing in-correct


Valves leaking Rework valve seatsFor other possible causes see also "Engine starts over but does not start engine or starts hard"

Engine runs irregularly at higher speed

Fuel pressure too low Check fuel pressure sensor, fuel pump and fuel supply

Leak air Check / replace intake socketCamshafts worn Check and replace if necessaryFor other possible causes see also "Engine starts over but does not start engine or starts hard"

C.3

NUDA 900 2012 - NUDA 900 R 2012


TROUBLESHOOTING


Engine has no or insufficient performance

Leak air, intake system leaking Check / replace intake socketSpark plugs not according to specifications or defective Replace spark plug

Valve clearance not according specifica-tion

Adjust valve clearance according to spe-cification

Valve timing incorrect Adjust position of camshaft gearsIgnition coil supplies insufficient ignition voltage Check / replace ignition coil



Valves leaking Exchange valves, rework valve seatsClutch slipping See remedies "clutch is slipping".

Fuel pressure too low Check fuel pressure sensor, fuel pump and fuel supply

Air filter dirty ExchangeExhaust system defective ExchangeExcessive Blow-by gases, Piston rings and/or cylinder bore worn Exchange piston rings and/or cylinder

Engine oil not according to specifications Exchange engine oil

Engine knocks or pings

Fuel of too low octane number Use fuel of specified octane number (min. ROZ 95)

Spark plugs not according to specifications or defective Replace spark plug

Leak air, intake system leaking Check / replace intake socket and intake system



Engine overheats

Not enough coolant in cooling system, coo-ling system leaking, air in cooling system

Refill coolant, check system under pres-sure

Cooling fan motor defective Replace cooling fan motorNot enough engine oil in the engine Refill oilRadiator dirty Clean radiatorThermostat defective Replace thermostatIgnition unit defective, ignition timing in-correct

Check / replace crank position trigger, ECU and sensors

Water pump, water pump drive defective Repair water pump, check and renew water pump drive

Oil pump or oil pump drive defective, re-taining ring for oil pump gear not fitted, oil circuit blocked

Exchange oil pump or oil pump gears, assemble retaining ring for oil pump gear, clean oil circuit

Cylinder head gasket defective Exchange cylinder head gasketLeak air Check / replace intake socket

Engine temperature is too low Thermostat defective Replace thermostat

C.4

NUDA 900 2012 - NUDA 900 R 2012

TROUBLESHOOTING



Engine produces excessive blue smoke or engine uses too much oil

Too much oil in the engine (oil in the ai-rbox) Drain engine oil

Cylinder head gasket leaking Exchange cylinder head gasketValve stem seals leaking Exchange valve stem sealsOil diluted with fuel / Piston rings and/or cylinder bore worn Exchange piston rings and/or cylinder

V-ring on water pump drive gear worn/missing Replace V-ring

Oil diluted with fuel / motocycle is only used in short distances (cold engine)

Use motorcycle at long distances in between

Engine vibratesEngine fixation into frame loose Tighten engine fixation

Bearing or bearing seat worn Replace bearing or worn component

Engine oil quantity increases

Oil diluted with fuel / motocycle is only used in short distances


Oil diluted with fuel / Piston rings and/or cylinder bore worn Exchange piston rings and/or cylinder

Low or no engine oil pressure

Not enough engine oil in the engine Refill oil

Pressure regulating piston blocked (bypass valve stuck in opened position) Check/replace pressure regulating piston

Oil pump and/or oil pump drive defective Check / replace oil pump and/or oil pump drive

Ignition cover gasket leaking into inside of engine (leakage of oil pressure circuit)

Replace ignition cover gasket and tighten ignition cover with correct touque

Oil pump worn Replace oil pump

Oil diluted with fuel / Piston rings and/or cylinder bore worn Exchange piston rings and/or cylinder

Oil diluted with fuel / motocycle is only used in short distances


Oil sieve / oil filter dirty/blocked Clean / replace oil sieve and replace oil filter

High engine oil pressurePressure regulating piston blocked (bypass valve stuck in closed position) Check/replace pressure regulating piston

Oil circuit blocked Clean oil ducts

C.5

NUDA 900 2012 - NUDA 900 R 2012


TROUBLESHOOTING


Engine excessively noisy

Noise is heard when the engine is started:Sprag clutch, sprag clutch housing or fre-ewheel gear worn

Replace Sprag clutch, sprag clutch housing or freewheel gear

Teeth of starter motor and/or starter drive gears worn

Replace starter motor and/or starter drive gears

Chain tensioner does not work Noise disappears after the engine is started when oil pressure is available

Noise seems to come from the valve train:

Excessive valve clearance Adjust valve clearance according to spe-cification

Chain tensioner does not work Replace chain tensioner

Camshaft or brackets of camshaft worn Replace camshafts and/or cylinder head

Camshaft drive worn or loose Tighten or replace camshaft gears

Camshaft chain, chain guide or chain tension guide worn

Replace camshaft chain, chain guide or chain tension guide

Noise seems to come from the piston:

Piston or cylinder worn Replace piston or cylinder

Piston pin bore or piston pin worn Replace piston pin bore or piston pin

Piston rings broken or ring grooves worn Replace piston rings broken or ring groo-ves

Noise seems to come from the crankshaft or balancing swing arm or crankcase:

Bearings of crankshaft or conrods worn Replace crankshaft and/or conrod bearings and /or replace crankshaft and conrods

Needle bushing and /or bearings of balan-cing swing arm and/or balancing rod worn

Replace balancing swing arm with balan-cing rod

Noise seem to come from the clutch or clutch side:Friction plates (hammer heads) and/or clutch drum worn

Replace friction plates and /or clutch drum

Excessive or insufficient backlash of the teeth of the primary drive gears Replace primary drive assy.

Clutch drum, clutch hub or pressure plate worn

Replace clutch drum, clutch hub or pres-sure plate

Bearing of clutch gear worn Replace primary drive assy.

Disk springs of primary drive assy. worn Replace primary drive assy.

Springs and spring retainers of primary drive assy. Worn Replace springs and spring retainers

Noise with clutch engaged - ball bearing of the pressure plate worn Replace ball bearing

Noise seem to come from the gearbox:

Tooth flanks of the gearbox gears worn Check gears and gear shafts, replace if necessary

Ball bearing of gearbox shafts and/or needle bearings of gears worn Replace bearings

C.6

NUDA 900 2012 - NUDA 900 R 2012

TROUBLESHOOTING



Clutch slips

Fatigue of clutch springs Replace clutch springs

Clutch plates worn or warped Replace clutch plates


Clutch disengages unsatisfactorily


Clutch plates warped Exchange clutch plates

Clutch plates stuck together Clean or exchange

Clutch "drags" at engagement

Clutch plates worn or warped Replace clutch plates

Guide slots for friction plates in clutch drum are worn Replace clutch drum

Guide slots for steel plates in clutch hub are worn Replace clutch hub

Gears do not engage or gears jump out at start or at abrupt acceleration

Gearshifting action incomplete Always actuate gearshift lever till stop

Gearshift lever incorrectly adjusted Correct position of gearshift lever

Fastener of gearshift lever loose Tighten fastener

Gearshift lever bent Replace gearshift lever

Function of index lever or index spring imperfect

Check index lever and index spring and exchange if necessary

Adjustment of gearshift pawl incorrect Check and adjust pawl wich spring, exchan-ge if necessary

Engagement teeth and/or windows of ge-arbox gears badly worn Exchange gears

Gearshift forks are worn or bent Exchange gearshift forks

Gearbox gears are worn or damaged Exchange gearshift gearbox gears

Clutch does not disengage See "Clutch disengages unsatisfactorily"

Gears can be shifted only noisily Clutch does not disengage See "Clutch disengages unsatisfactorily"

Spark plugs overheated, burnt or dirty

Spark plugs not according to specifica-tions Replace spark plug

Spark plugs loose Tighten spark plugs

Intake socket not tight or leaking Tighten intake socket or exchange if ne-cessary

Fuel supply system defective Check and replace if necessary

Generator does not charge or chargs incorrectly

Battery faulty, loose or corroded connec-tions

Check/replace battery and check connec-tions

Rectifier regluator defective Replace rectifier regluator

Break in current, short circuit or earthing of stator windings Replace stator

Break in cables or short circuit, connections loose Check and replace if necessary

C.7

NUDA 900 2012 - NUDA 900 R 2012


TROUBLESHOOTING

CHASSIS

Trouble Cause Remedy

Handlebar turns hard

Insufficient tyre pressure InflateBearing adjuster ring nut or steering stem nut overtightened Adjust

Bent steering stem Replace bottom yoke

Worn or seized steering bearings Replace

Handlebar vibration

Bent fork legs ReplaceBent front wheel axle ReplaceWarped chassis ReplaceBent front wheel rim ReplaceWorn front wheel bearings ReplaceImproperly balanced wheel Balance

Damping is too hard

Too much oil in fork legs Remove excess oilFork oil viscosity too high ChangeOverinflated tyres DeflateImproperly set rear shock absorber Adjust

Damping is too soft

Insufficient oil in fork legs Top upFork oil viscosity too low ChangeWeak fork springs ReplaceWeak rear shock absorber spring ReplaceImproperly set rear shock absorber Adjust

(Front / rear) wheel shakes

Bent wheel rim ReplaceWorn wheel hub bearings ReplaceWheel axle nut loose TightenWorn rear swinging arm bearings ReplaceImproperly balanced wheel Balance

Rear suspension is noisyWorn shock absorber ball joints ReplaceShock absorber faulty Replace

Poor braking (front and rear)

Air in brake system BleedInsufficient fluid in tank Top upWorn brake pad and/or disc ReplaceDamaged disc Replace

C.8

NUDA 900 2012 - NUDA 900 R 2012

TROUBLESHOOTING


ELECTRICAL SYSTEM (see also Section M)

Trouble Cause Remedy

Spark plug fouls easilyDirty air filter CleanWorn piston rings ReplaceWorn piston or cylinder liner Replace

Spark plug electrodes overheatSpark plug electrode gap too close AdjustWrong heat rating Replace with recommended spark plug

Generator does not charge or is not providing enough charge

Cables running to voltage regulator im-properly connected or shorted Connect correctly or replace

Voltage regulator faulty ReplaceFaulty generator Replace

Generator overcharges battery Voltage regulator faulty Replace

Battery does not hold chargeBattery terminals dirty CleanFaulty generator ReplaceFaulty battery Replace

Starter motor does not start or slips

Battery is flat ChargeControl on R.H. switch faulty ReplaceStarter relay faulty ReplaceStarter motor faulty Repair or replaceWorn starter gears ReplaceWorn or damaged freewheel rollers Replace freewheelIgnition key not recognised Check control unit key immobiliser

C.9

NUDA 900 2012 - NUDA 900 R 2012


TROUBLESHOOTING

D.1

NUDA 900 2012 - NUDA 900 R 2012

D


SETTINGS AND ADJUSTMENTS

Section

D.2

NUDA 900 2012 - NUDA 900 R 2012



Saddle removal.............................................................................................D.3Central cover removal ..................................................................................D.4Side panel removal .......................................................................................D.5Throttle cable adjustment .............................................................................D.5Throttle control..............................................................................................D.6Front brake control .......................................................................................D.6Front brake lever adjustment and fluid level check .....................................D.7Clutch control................................................................................................D.8Throttle position adjustment .........................................................................D.8Clutch free play adjustment ..........................................................................D.9Rear brake pedal free play adjustment.........................................................D.9Rear brake fluid level check .......................................................................D.10Oil level check ............................................................................................D.10Engine oil replacement and cartridge filter replacement ............................D.11Coolant level check ....................................................................................D.12Coolant replacement ..................................................................................D.12Air filter check .............................................................................................D.15Chain adjustment .......................................................................................D.16Lubricating the chain ..................................................................................D.17Suspension .................................................................................................D.18Suspension settings summary tables .........................................................D.18Rear shock absorber ..................................................................................D.20Spring preload adjustment NUDA 900........................................................D.21Spring preload adjustment NUDA 900 R ....................................................D.22Adjustment shock absorber length NUDA 900 R........................................D.23Shock absorber hydraulic damping adjustment..........................................D.24Fork adjustment NUDA 900 .......................................................................D.25Fork adjustment NUDA 900 R ....................................................................D.25Fuel supply hose inspection and replacement ...........................................D.26Exhaust system check ................................................................................D.27ed adjustment .............................................................................................D.27

D.3

NUDA 900 2012 - NUDA 900 R 2012

H10662

1

H10663

2



Saddle removalTurn the pin (1) counter-clockwise at approx. 90° and remove the saddle (2) to the rear part unhooking it from the front brackets.

D.4

NUDA 900 2012 - NUDA 900 R 2012

H10664

1

H10665

2

H10666

3

3

3

H10667

4

H10668

4

35

35

5

3a



Central cover removal- Insert the key in the lock and remove the cap (1).

- Remove the screw (2) under the cap.

- Loosen the five screws (3) that fasten the cover (4) and remove it.

- Reinstall the reservoir cap (1) to prevent that objects from accidentally falling into it.

During the reassembly, position correctly the bushings (5) ensur-ing the that longest screws (3a) are tightened in the rear part of the cover.

D.5

NUDA 900 2012 - NUDA 900 R 2012

H10669

2

1

11a

1

H10670

2 mm(0,08 in.)

1

H10906

2 3

4



Side panel removal- Remove the saddle as described in the relevant paragraph.

- Loosen the five screws (1) and remove the right-hand side (2).

- Perform the same procedures for the removal of the left-hand side.

During the reassembly, tighten the screws with the respective bushings, and position the M6 screw (1a) in the centre part of the side.

Throttle cable adjustment

To check the correct adjustment of the throttle control cable, operate as follows:- remove the reservoir and the filter box as outlined in the relevant sections;- turn throttle twistgrip (1) and make sure that there is a clearance of approx.

2 mm (0.08 in);- if this does not work, unlock the check nut (2);- work on the nut (3) until you have about 2 mm clearance (0.08 in.);- tighten check nut (2).- reassemble all parts, in the reverse order compared to disassembly.

Operation with damaged throttle cable could result in an unsafe riding condition.

When throttle control cables (4) are replaced, adjust new cables as previously explained.

D.6

NUDA 900 2012 - NUDA 900 R 2012

H10672

1

2

2

H10673

1

2

2



Throttle controlThe throttle twistgrip is located on the right-hand side of the handlebar:

Throttle position adjustmentThe position of the control on the handlebar can be adjusted by loosening the two retaining screws (2).

Do not forget to tighten the screws (2) after adjusting.

Front brake controlThe brake control lever (1) is located on the right-hand side of the handlebar.

Position adjustmentThe position of the control on the handlebar can be adjusted by loosening the two retaining screws (2).

After adjustment, turn the handlebar as far as possible to the right and make sure that the lever does not touch the bodywork

A stop switch, during the braking action, causes the stop light on the tail light to come on.


D.7

NUDA 900 2012 - NUDA 900 R 2012

H10675

2A

H10674

1

H10676

4

MAX

MIN3



Front brake lever adjustment and fluid level checkThe lever (1) can be set to five different positions according to the size of the rider’s hand. To decrease the lever (1) distance from the handgrip, turn the adjuster screw (2) COUNTER CLOCKWISE “A”. Fluid level inside master cylinder tank shall never be below the min. level (3) indicated on the transparent tank (4).A decrease of the fluid level will let air into the system, hence an extension of the lever stroke.

If the brake lever feels mushy when pulled, there may be air in the brake line or the brake may be defective: CHECK THE BRAKING SYSTEM (see Section "L").

Too much brake lever free play may reduce braking action: CHECK BRAKE PAD THICKNESS (see Section "L").

Do not spill brake fluid onto any painted surface or lens (for example lights lens).

Do not mix two brands of fluid. Completely change the brake fluid in the brake system if you wish to switch to another fluid brand.

Brake fluid may cause irritation. Avoid contact with skin or eyes. In case of contact, flush thoroughly with water and call a doctor if your eyes were exposed.

D.8

NUDA 900 2012 - NUDA 900 R 2012

H10677

1

2

2

H10678

1

H10679

2

A

B



Clutch controlThe clutch control lever (1) is located on the left-hand side of the handlebar.

Position adjustmentThe position of the clutch control on the handlebar can be adjusted by loosening the retaining screws (2).

After adjustment, turn the handlebar as far as possible to the left and make sure that the lever does not touch the bodywork.


Clutch control lever distance adjustmentThe lever (1) distance on the handlebar can be adjusted according to the size of the rider's hand.

To adjust the lever distance (1) from the handgrip, push the lever (1) outwards and hold it in position, then work on the adjuster screw as explained thereafter.- To move the lever away from the handgrip, turn the adjuster screw (2) clock-

wise (A);- To move the lever closer to the handgrip, turn the adjuster screw (2) counter-

clockwise (B).

Release the lever.

D.9

NUDA 900 2012 - NUDA 900 R 2012

H10681

1

2

H10682

B

1

H10680

A

H10683

2

3

D

C



Clutch free play adjustmentFree play (A) must be 5 -10 mm (0.196 - 0.39 in).It can be adjusted by turning and adjuster screw on the clutch cover.- Loosen the check nut (1) and adjust play by turning the threaded pin (2); -

after adjustment tighten the nut (1).

Rear brake pedal free play adjustmentBefore staring the braking action, rear brake pedal (1) shall have a free play (B) of 5-10 mm (0,196 ÷ 0,39 in.). Should this not happen, operate as follows:- Loosen the nut (2);- Operate the master cylinder linkage (3) to increase or decrease free play;- Tighten the nut (2) at the end of the operation.

When the free play requirement is not met, the brake pads will be subjected to an early wear that may lead to TOTAL BRAKE INEF-FECTIVENESS.

If the brake pedal feels mushy when pulled, there may be air in the brake line or the brake may be defective. CHECK THE BRAKING SYSTEM (see Section L).

C: to increase clearanceD: to decrease clearance

D.10

NUDA 900 2012 - NUDA 900 R 2012

H10684

1 MIN

MAX

2

H10685

1

2

3

MIN

MA

X

MIN

MAX



Rear brake fluid level checkThe fluid level in the master cylinder tank shall never be below the minimum level (1) shown on the transparent reservoir (2).A decrease in the fluid level will let air into the system and increase the lever stroke.

If the brake pedal feels mushy when pulled, there may be air in the brake lines or the brake may be defective.

Do not spill brake fluid onto any painted surface or light lens.



Oil level check- Start vehicle as described in the relevant section, let it run for approx. 3 min-

utes so as to warm engine up.- Stop the engine.- Keeping the motorbike upright and on even ground, wait a few minutes for

the oil to reach the sump.- Check the level as follows: - Undo the cap (1) with the dipstick (2) and remove it from the engine. - Clean the dipstick (2) with a cloth. - Place the dipstick (2) in the hole (3) without screwing the cap on. - Remove the dipstick (2) from the hole (3) and check that the level is

between the two MIN and MAX marks. - To top up, pour oil into the hole (3); for the type of oil, see the section “Techni-

cal data”.

D.11

NUDA 900 2012 - NUDA 900 R 2012

H10686

1

4

H10687

3

H106882



Engine oil replacement and cartridge filter replacement

Be careful not to touch hot engine oil.

Drain the oil with WARM ENGINE; proceed as follows:- Place the motorcycle on the side stand;- remove oil filler cap (1);- place a pan under the engine drainage plug;- remove oil drainage plug (2);- drain the exhausted oil, and clean magnet on plug (2);- using a suitable tool, unscrew the cartridge filter (3) and remove it;- replace the filter (3) with a new one and clean the contact surfaces between

the filter and the crankcase before screwing it up, lubricate the seal with en-gine oil and hand tighten it.

- screw the drainage plug (2) up again and replace the seal;- pour the recommended quantity of oil into the oil hole (4);- refit the oil drainage plug (1).

Switch on the engine for a short period of time to allow the oil to reach all parts of the engine and check the level as described in the relevant section.

D.12

NUDA 900 2012 - NUDA 900 R 2012

H10689

1

MAX

MIN

H10907

2

1

3

H10691

1



Coolant level checkWhen the engine is cold, check that the coolant level is between the two MIN and MAX marks on the expansion tank (1) on the right side of the vehicle.If topping up is necessary, do the following:- Remove the saddle and side panels, as described in the relevant sections.

Do not remove the radiator cap (2) since all the liquid in the expan-sion tank (1) will flow out.

- Remove the cap (3) and add the fluid needed to restore the level to the ex-pansion tank (1).

(for the type of liquid to use, see the section “Technical data”).

Difficulties may arise in eliminating coolant from painted surfaces. If this occurs, wash off with water.

Coolant replacement- Put the motorbike in a vertical position.- Remove the saddle, the right-hand side as outlined in the relevant sections.- Put a 2 Lt bucket under the engine.

- Loosen the screw (1) on the engine head and let the coolant drain.

D.13

NUDA 900 2012 - NUDA 900 R 2012

H10692

2

5

3

H10693

3

5

6

H10694

4

7

H10695

8



- Loosen the screw (2) of the lower pipe (3) that connects the radiator (4) to the exchanger (5).

- Remove the exchanger pipe (3) and let the coolant drain in the bucket; dur-ing the reassembly, replace the seal (6).

- Open the clamps (7) and remove the pipes (8) from the radiator allowing the coolant to drain fully from the radiator.

-- Reassemble all previously removed components in the reverse order.

- Put the motorbike on the side stand.

D.14

NUDA 900 2012 - NUDA 900 R 2012

H10696

4

9

11

12

MAX

MIN

H10697

10



- Remove the radiator cap (9).

- Loosen the coolant bleed screw (10) on the water pump cover and at the same time continue to pour liquid in the radiator until it comes out of the hole of the bleed valve, then tighten again the bleed valve (10).

- Top up with coolant until the maximum level of the radiator (cap upper bor-der).

- Refit the radiator cap (9).

- Start the engine and leave it on until the radiator is warm, then turn off the engine and leave it to cool down for around 2-3 minutes.

- Turn the radiator cap (9) until the 1st safety notch and let the possible pres-sure discharge, then remove the cap.


- Restart the engine and repeat the procedures until the level of the radiator liquid reaches the maximum level.


- Remove the expansion tank (12) cap (11) and pour in liquid until the level is between the minimum and the maximum level.

- Refit the cap (11).

D.15

NUDA 900 2012 - NUDA 900 R 2012

H10698

2

12

H10699

3

34

H10700

5

H10701

5



Air filter check- Remove the upper cover as described in the relevant section.

- Disconnect connector (1) of the air temperature sensor.- Unscrew the two screws (2) that fasten the side panels at the front.

- Unscrew the screws (3) on the filter cover (4) and remove it.

- Clean the area around the filter (5) before removing it.

- Remove the filter (5), check that it is not clogged and replace if necessary.

Before refitting the filter, check that the contact surfaces between the filter, the filter box and the cover are completely clean.

D.16

NUDA 900 2012 - NUDA 900 R 2012

H10702

A

1

2

H107033

45

6

H10704

4 5

6



Chain adjustment Chain should be checked, adjusted and lubricated as per the Maintenance Chart to ensure safety and prevent excessive wear.If the chain becomes badly worn or is adjusted incorrectly (i.e., it is too loose or too tight), it could jump out of the sprocket or break.

Check that distance "A" between the chain (1) and the bottom part of the slider (2) measures 25 ÷ 30 mm (0.984 ÷ 1.181 in):When the vehicle is running,the chain must not hit the bottom part of the slider (2).

If this is not the case, proceed as follows:- make sure that the motorcycle is fully upright on the special rear support

stand (optional).

- on the left side, loosen the locking nut (3) of the wheel axle;- loosen the check nuts (5) on both chain tensioners;- turn the adjuster screws (4) to obtain the correct tension and check on both

sides that the wheel centring sliders (6) are in the same position as the mark-ings in the chain tensioner slider seats on the swinging arms;

- once adjusted, tighten the check nuts (4) and the wheel axle nut (3). After adjusting, always check that distance "A" is 25 ÷ 30 mm (0.984 ÷ 1.181

in).

D.17

NUDA 900 2012 - NUDA 900 R 2012



Lubricating the chainLubricate the chain following these instructions.

Never use grease to lubricate the chain. Grease helps to accumulate dust and mud, which act as abrasive and help to rapidly wear out the chain, the front and rear sprockets.

Do not wash the chain with high-pressure water jets and do not use harsh or highly flammable solvents.

- After washing the chain using special detergent, dry it and lubricate with suit-able spray grease.

The chain lubricant must NOT come into contact with the tyres or the rear brake disc.

D.18

NUDA 900 2012 - NUDA 900 R 2012



Suspension The vehicle leaves the factory with standard settings for the front and rear suspension that meet most requirements.

On "NUDA 900" motorcycles, the front fork cannot be adjusted whereas the hydraulic rebound on the rear shock absorber can be adjusted.

On "NUDA 900 R" motorcycles the suspension can be adjusted according to the type of use and load.The motorcycle suspension can be adjusted for track use only (Motard version).

The Motard version suspension has been designed exclusively for track use. Road use is not recommended.

NOTE: Before making any change and afterwards, if the adjustment is not satisfactory, always start from the standard suspension setting and increase or decrease the adjusting clicks, one at a time.

The various adjustments must be made on the front fork and the rear shock absorber as described in the following tables.

Suspension settings summary tables

SHOCK ABSORBER NUDA 900 NUDA 900with panniers and passenger

NUDA 900 R NUDA 900 RMotard

NUDA 900 Rwith panniers and passenger

Length of shock absorber "A" - - 380 mm(14,96 in)

385 mm (15,15 in)

380 mm (14,96 in)

Shock absorber compression adjustment

- - 16 clicks 14 clicks 16 clicks

Shock absorber rebound adjustment

25 clicks 10 clicks 18 clicks 9 clicks 18 clicks

Shock absorber spring constant "K"

105 N/mm 105 N/mm 100 N/mm 100 N/mm 100 N/mm

FORK NUDA 900 NUDA 900with panniers and passenger


NUDA 900 Rwith panniers and pas-senger

Compression adjustment - - 6 clicks 3 clicks 6 clicksRebound adjustment - - 10 clicks 10 clicks 10 clicksFork spring constant "K" 6,5 N/mm

7,0 N/mm(RBND)

6,5 N/mm7,0 N/mm (RBND)

7,0 N/mm7,0 N/mm

7,0 N/mm7,0 N/mm

7,0 N/mm7,0 N/mm

Position of fork "A" 220 mm (8,66 in) 220 mm (8,66 in) 230 mm(9,05 in)

240 mm (9,45 in)

230 mm (9,05 in)

D.19

NUDA 900 2012 - NUDA 900 R 2012

H10705

A

H10706

“A” =

385 m

m (N

UDA

900 R

Mota

rd)

“A” =

380

mm

(NUD

A 90

0)

“A” =

380

mm

(NUD

A 90

0 R)



NOTE: Fork springs and shock absorbers with varying degrees of stiffness are available above all for use with passenger and/or panniers.

NOTE: Do not go beyond 385 mm.

D.20

NUDA 900 2012 - NUDA 900 R 2012

H10706

“A” =

385 m

m (N

UDA

900 R

Mota

rd)

“A” =

380

mm

(NUD

A 90

0)

“A” =

380

mm

(NUD

A 90

0 R)



Rear shock absorberDepending on the installed rear shock absorber model, it is possible to per-form different adjustments as reported in the following table:

SHOCK ABSORBER NUDA 900 NUDA 900with panniers and passenger


NUDA 900 Rwith panniers and passenger

Length of shock absorber "A" - - 380 mm(14,96 in)

385 mm (15,15 in)

380 mm (14,96 in)

Shock absorber compression adjustment


Shock absorber rebound adjustment


Shock absorber spring constant "K"


Besides the adjustments in the table, it is possible to adjust the spring preload as follows:

D.21

NUDA 900 2012 - NUDA 900 R 2012

H10707

1

2

3

H10959

111,2 mm (4,38 in.) 162,5 ± 1,5 mm (6,4 ± 0,06 in.)

NUDA 900380 ± 1,5 mm (14,96 ± 0,06 in.)

A

B



Spring preload adjustment NUDA 900- Remove the fuel tank as described in the relevant paragraph.- Clean the lock ring nut (1), and adjuster ring nut (2) on the spring (3) and the

threading on the body of the shock absorber.- Loosen lock ring nut using a hook spanner.- Turn adjuster ring nut until reaching the desired position.- After having adjusted the suspension based on your weight and riding style,

tighten lock ring nut (tightening torque 10 Nm; 1.02 Kgm; 7.38 ft-lb).

A: Wheelbase.B: Spring in its seat.

D.22

NUDA 900 2012 - NUDA 900 R 2012

H10908

1

2

3

H10960

ANUDA 900 R

181 mm (7,13 in.)

380 ± 1,5 mm14,96 ± 0,06 in.

B



Spring preload adjustment NUDA 900 RProceed as follows:1. Clean the lock ring nut (1), the adjuster ring nut (2) on the spring (3) and the

threading on the body of the shock absorber.2. Either with a hook wrench or an aluminium punch, loosen the lock ring nut.3. Turn the adjuster ring nut as required.4. Adjust preload to suit your weight or riding style and tighten the lock ring nut

firmly (tightening torque 10 Nm - 1 Kgm - 7.38 ft-lb).

Be careful not to touch hot exhaust pipe while adjusting the shock absorber.

A: Spring in its seat (free length 190 mm / 7.48 in.).B: Wheelbase.

D.23

NUDA 900 2012 - NUDA 900 R 2012

H10916

1

2

5

H10915

NUDA 900 R

380 ÷ 385 mm14,96 ÷ 15,16 in.

5

H10917

5

34

5



Adjustment shock absorber length NUDA 900 R

- Remove the fuel tank as described in the relevant paragraph.

- Loosen the upper pin (1) that fastens the shock absorber (2) to the chas-sis.

- Move the shock absorber (1) from the chassis, loosen the nut (3), then turn the eyelet terminal (5) to adjust the length.

NOTE: At each full turn of the eye terminal, the length varies by 1 mm (0.04 in.).

- After the length adjustment, tighten the nut (3).

The maximum allowed length of the shock absorber between the eyelet terminal axle and the lower fork axle is 385 mm (15.16 in.).

Do not exceed the 385 mm length and do not exceed for any reason the safety slot (4) on the threaded leg of the terminal (5).

D.24

NUDA 900 2012 - NUDA 900 R 2012

H10713

1

+

-

H107142

+

-

H10715

+

- 3



Shock absorber hydraulic damping adjustment

Nuda 900The shock absorber can be adjusted in the rebound hydraulic damping.

B) REBOUND - Standard setting:Adjuster 1:- 25 clicks (± 2 clicks) To reset the standard setting, turn lower adjuster (1) clockwise until reaching fully closed position. Then turn it back the number of clicks specified above.In order to obtain a smooth braking action, turn the adjuster counter clockwise. Vice versa to obtain a harder braking action.

Nuda 900 RThe shock absorber has adjustable hydraulic compression and rebound damp-ing.

A) COMPRESSION - Standard setting:Adjuster 2:- 16 clicks (± 2 clicks)

B) REBOUND - Standard setting:Adjuster 3:- 11 clicks (± 2 clicks)

To reset the standard setting, turn the lower adjuster screw (2) and the upper adjuster screw (3) clockwise until reaching fully closed position. Then turn it back the number of clicks specified above.If you want to work on the adjuster screw (3), remove the right-hand panel.Turn the adjuster screw clockwise to increase compression damping or coun-terclockwise to decrease it.

D.25

NUDA 900 2012 - NUDA 900 R 2012

H10716

A

+

-

H10717

BC

+

-



Fork adjustment NUDA 900 On the fork installed on this motorbike version, it is not possible to perform any type of adjustment.

Fork adjustment NUDA 900 Ra) COMPRESSION (LOWER ADJUSTER)Standard setting: 6 clicks 900 R 3 clicks 900 R Motard

To reset standard calibration, turn adjuster screw (A) clockwise to reach the fully closed position; then turn it back the number of clicks specified above. Turn the adjuster screw clockwise to increase compression damping or coun-terclockwise to decrease it.

b) REBOUND (TOP ADJUSTER)Standard setting: 10 clicks

To reset standard calibration, turn adjuster screw (B) clockwise to reach the fully closed position and then turn it back the number of clicks specified above. Turn the adjuster screw clockwise to increase rebound damping or counter-clockwise to decrease it.

Never force the adjusting screws beyond the maximum open and closed positions.

c) PRELOAD ADJUSTMENTTo adjust, turn the central nut (C) on the cap. Turn the nut clockwise to increase the spring preload and counterclockwise to decrease it.

FORK NUDA 900 R NUDA 900 RMotard


Compression adjustment 6 clicks 3 clicks 6 clicksRebound adjustment 10 clicks 10 clicks 10 clicksFork spring constant "K" 7,0 N/mm

7,0 N/mm7,0 N/mm7,0 N/mm

7,0 N/mm7,0 N/mm

D.26

NUDA 900 2012 - NUDA 900 R 2012

H10918

1

2

3

6

H10719

4

6

H10720

15



Fuel supply hose inspection and replacementCheck fuel supply hose (1) conditions; if cracked, swollen, kinked, etc. it is nec-essary to change it as follows:

- Remove the saddle, the right-hand side as outlined in the relevant sections.

- Open the clamp (2) and disconnect the hose (1) from the coupling (3).

- Cut the clamp (4).

- Remove the filter box as described in the relevant section.

- Open the clamp (5) and disconnect the hose (1).

During the reassembly, make sure that the clamp (4) is positioned on the rubber protection and that the hose (1) goes under the protection bracket (6).

During this operation, make sure that you do not damage the hose holder coupling on the throttle body.

D.27

NUDA 900 2012 - NUDA 900 R 2012

H10919

H10920

1 1

H10921

2

H10922

3



Exhaust system checkPerform a visual inspection of the exhaust system first, in order to identify pos-sible gas leaks from the sealing elements (gaskets), and to ensure that the Silent-Blocks are not damaged.

Subsequently, inspect the single components by disassembling the exhaust system.

Moreover, check the tightening of the flanges nuts (1) that fasten the manifold to the cylinder head and of the fastening clamp (2) of the silencer to the mani-fold, as well as the tightening of the screw (3) that retains the silencer to its support.

The damaged or broken parts must be replaced.

Idle speed adjustmentThe idle speed is pre-set by the control unit (1250 rev/min.) and the stepper motor ensures that this value is preserved.No manual adjustment is possible, nor any adjustment through the diagnostic tool.

E.1

NUDA 900 2012 - NUDA 900 R 2012

E


GENERAL PROCEDURES

Section

E.2

NUDA 900 2012 - NUDA 900 R 2012

GENERAL PROCEDURES


Stand removal / replacement........................................................................E.3Stand foot replacement ................................................................................E.4Saddle removal.............................................................................................E.5Air-Box cover removal ..................................................................................E.6Side panels removal .....................................................................................E.7Number plate holder removal .......................................................................E.7Tail light removal ...........................................................................................E.9Rear turning indicator removal. ..................................................................E.10Tail removal ................................................................................................E.13Front fairing removal...................................................................................E.14Front turning indicator removal ...................................................................E.15Combined dashboard removal ...................................................................E.16Front mudguard removal ............................................................................E.17Front mudguard fin removal .......................................................................E.18Battery removal ..........................................................................................E.19Reservoir removal ......................................................................................E.20Fuel pump removal .....................................................................................E.22Fuel pump test ............................................................................................E.23Filter box removal .......................................................................................E.24Throttle body removal ................................................................................E.25Exhaust system removal ............................................................................E.27Exhaust system removal ............................................................................E.28Lambda sensor removal .............................................................................E.30Coil / Stick-Coil removal and spark plug test .............................................E.31Horn disassembly .......................................................................................E.32Radiator removal ........................................................................................E.32Electric fan removal ....................................................................................E.34Gearbox lever removal ...............................................................................E.34Battery housing removal .............................................................................E.35Engine removal...........................................................................................E.37Engine reassembly .....................................................................................E.40

E.3

NUDA 900 2012 - NUDA 900 R 2012

H10722

1

2

H10723

2

H10909

3

H10725

54

H10727

12

3

4

5

6


GENERAL PROCEDURES

Stand removal / replacement- Loosen the nut (1) and remove the rotary type switch (2).

- Release the spring (3).

- Loosen the screw (4) and remove the stand (5).

- During the reassembly, grease the screw (4) and reassemble correctly the bushing (6).

The screw (4) must be replaced at every disassembly.

NOTE: For the correct installation of the rotatory type switch (2), refer to chapter "M".

E.4

NUDA 900 2012 - NUDA 900 R 2012

H10726

7

8

H10728

8

GENERAL PROCEDURES


Stand foot replacement- Loosen the screw (7) and replace the foot (8) by reinstalling it exactly as the

figure shows.

E.5

NUDA 900 2012 - NUDA 900 R 2012

H10662

1

H10663

2


GENERAL PROCEDURES

Saddle removalTurn the pin (1) around 90° counter-clockwise and remove the saddle (2) to the rear part unhooking it from the front brackets.

E.6

NUDA 900 2012 - NUDA 900 R 2012

H10664

1

H10665

2

H10666

3

3

3

H10667

4

H10668

4

35

35

5

3a

GENERAL PROCEDURES


Air-Box cover removal- Insert the key in the lock and remove the cap (1).

- Remove the screw (2) under the cap.

- Loosen the five screws (3) that fasten the cover (4) and remove it.

- Reinstall the reservoir cap (1) to prevent objects from accidentally falling into it.

During the reassembly, correctly position the bushings (5) ensuring the that longest screws (3a) are tightened in the front part of the cover.

E.7

NUDA 900 2012 - NUDA 900 R 2012

H10669

2

1

11a

1

H10729

1

2

H10730

34

H10731

5

6


GENERAL PROCEDURES

Side panels removal- Remove the saddle as described in the relevant paragraph.

- Loosen the five screws (1) and remove the right-hand side (2).

- Perform the same procedures to remove the left-hand side.

During the reassembly, tighten the screws with the respective bushings, and position the M6 screw (1a) in the centre part of the side.

Number plate holder removal- Remove the saddle as described in the relevant paragraph.- Disconnect the two connectors (1) and (2) of the rear harness.

- Loosen the two screws (3) that fasten the number holder (4) to the chas-sis.

- Remove the saddle fastening pin (5) using a rubber hammer (during the reassembly, replace the plastic washer (6)).

E.8

NUDA 900 2012 - NUDA 900 R 2012

H10732

7

7

H10733

4

GENERAL PROCEDURES


- Remove the two upper screws (7).

- Tilt the number plate holder (4) to the right and to the left, and remove it.

E.9

NUDA 900 2012 - NUDA 900 R 2012

H107341

H10735

22

H10736

3


GENERAL PROCEDURES

Tail light removal- Remove the number plate holder as described in the relevant paragraph.- Remove the O-ring (1) that fasten the cables.

- Loosen the two screws (2) with the related bushings and remove the tail light (3).

E.10

NUDA 900 2012 - NUDA 900 R 2012

H10737

1

1

H10738

2

3

3

H10739

2

GENERAL PROCEDURES


Rear turning indicator removal- Remove the number plate holder as described in the relevant paragraph.- Remove the tail light as described in the relevant paragraph.- Loosen the two screws (1) that fasten the passenger handle (2).

- Remove the passenger handle (2); during the reassembly, make sure that the bushings (3) of the retaining screws of the tail light are positioned in the related seats.

E.11

NUDA 900 2012 - NUDA 900 R 2012

H107404

4

44

5

5

6

6

H10741

7

H10742

6

6

8 9


GENERAL PROCEDURES

- Loosen the four self-tapping screws (4).- Loosen the two screws (5) that retain the turning indicators (6).

- Remove the lower cover (7).

- Disconnect the two connectors (8) and (9), and remove the two turning indi-cators (6).

E.12

NUDA 900 2012 - NUDA 900 R 2012

H10743

10

12

13

H10744

11

H10745

14

GENERAL PROCEDURES


- In case of replacement of the harness (10), cut the clamp (11), disconnect the number plate bulb holder (12), replace the harness (10) and reinstall it exactly in the same position by fastening it with the clamp (11) and passing it behind the tab (13).

During the reassembly of the turning indicators, make sure that the water discharge hole (14) faces downwards and that the connector of the right-hand turning indicator is connected to the connector marked with a white adhesive tape of the bike harness.

E.13

NUDA 900 2012 - NUDA 900 R 2012

H10746

1

11

1

H10747

1

H10748

2


GENERAL PROCEDURES

Tail removal- Remove the saddle, the sides and the number plate holder as described in

the relevant paragraphs.- Loosen the five screws (1) and remove the tail (2) slipping it off towards the

rear part.

E.14

NUDA 900 2012 - NUDA 900 R 2012

H10749

1

H10750

2

GENERAL PROCEDURES


Front fairing removal- Loosen the two screws (1) and remove the spoiler (2).

E.15

NUDA 900 2012 - NUDA 900 R 2012

H10751

12

H10752

3

4

H10753

4

H10754

5


GENERAL PROCEDURES

Front turning indicator removal- Remove the front fairing as described in the relevant paragraph.- Disconnect the connector (1) of the left-hand indicator and the connector (2)

of the right-hand indicator.

- Loosen the screws (3) and fully remove the indicators (4).

During the reassembly of the turning indicators, make sure that the water discharge hole (5) faces downwards and that the connector of the right-hand turning indicator is connected to the connector marked with a white adhesive tape of the bike harness.

E.16

NUDA 900 2012 - NUDA 900 R 2012

H10755

1

H10756

2

H10757

3

GENERAL PROCEDURES


Combined dashboard removal- Remove the front fairing as described in the relevant paragraph.- Disconnect the connector (1).

- Remove the retaining clip (2) and remove the dashboard (3).

During the reassembly, insert the pins in the special rubbers and lock the dashboard with the special retaining clips.

After the replacement of the dashboard, it is necessary to connect the diagnostic tool to the vehicle and follow the wizard.

E.17

NUDA 900 2012 - NUDA 900 R 2012

H10758

1

1

2

H10759

2

H10760

1

2

3


GENERAL PROCEDURES

Front mudguard removal- Loosen the six screws (1) that fasten the mudguard (2) to the fork making

sure to retain the bushings (3).- Lift and slightly turn the mudguard (2), then remove it.

During the reassembly, insert again correctly the bushings (3) on the mudguard (2).

E.18

NUDA 900 2012 - NUDA 900 R 2012

H10761

12

H10762

3 4

GENERAL PROCEDURES


Front mudguard fin removal- Loosen the screw (1) and remove the fin (2); during the reassembly, fit the

tab (3) in the special seat (4), then tighten again the screw (1).

E.19

NUDA 900 2012 - NUDA 900 R 2012

H10763

1

1

1

H107642

H10765

3


GENERAL PROCEDURES

Battery removal- Make sure that the ignition switch has been turned to OFF and that the key

has been removed;– loosen the three screws (1);

- remove the cover (2);- first remove the BLACK or BLUE negative cable, then the RED positive cable

(when reassembling, first connect the RED positive cable, then the BLACK or BLUE negative cable);

- remove the battery (3) from its housing by easing it off from under the chassis beam.

Always check the battery charge before reinstalling it on the vehicle.

The battery should be kept clean and the terminals coated with neutral grease or petroleum jelly.

During the removal of the battery, avoid any contact between the poles of the battery and the metallic parts of the vehicle (e.g. chas-sis) in order to prevent the risk of short-circuits.

E.20

NUDA 900 2012 - NUDA 900 R 2012

H10766

1

2

2

3

H10767

4 5

H10768

6

7

H10769

8

GENERAL PROCEDURES


Reservoir removal- Disassemble the saddle, the sides, the number plate holder and the tail as

described in the relevant paragraphs.- Disconnect the oil pump supply connector (1).- Loosen the two screws (2) and remove the pump delivery fitting (3).

A small quantity of fuel can come out of the pipe.

- Cut the clamp (4) that retains the fuel pipe (5).- Move the fuel pipe (5).

- Remove the reservoir breather hose (6) from the cap flange (7).

- Loosen the reservoir centring screw (8).

E.21

NUDA 900 2012 - NUDA 900 R 2012

H10910

9

9 11

10

H10771

11

12

H10772

12

13

H10773

11

12

H10774

7

14

14


GENERAL PROCEDURES

- Loosen the four screws (9) (two per side) that fasten the small chassis (11) to the chassis (10).

- Remove the small chassis (11) with the reservoir (12) towards the rear side of the bike.

- Loosen the two screws (13) (one per side) and remove the small chassis (11) from the reservoir (12).

- Loosen the screws (14) and remove the cap flange (7).

During the reassembly, replace the screws (9).

E.22

NUDA 900 2012 - NUDA 900 R 2012

H10775

1

2

H10776

3

H10777

4

6

7

H10778

1

21

1

1

1

12

16

1

C

MAX

MIN

5

5

GENERAL PROCEDURES


Fuel pump removal- Disassemble the saddle as described in the relevant paragraph.- Disconnect the connector (1).- Disconnect the fuel pipe (2) by loosening the two screws; collect the fuel that

could come out.

- Use a suitable tool to loosen the ring nut (3) and remove the reservoir pump (4).

- Check the seal (5) for wear, change it if dry or damaged.

During the reassembly, make sure that the seal is in the correct position: the lip with the greater diameter must be installed facing outwards.

- Check the status of the O-ring seals, replace if damaged.

- During the reassembly of the pump the reference tab (6) on the pump (4) should coincide with the seat (7) in the reservoir ring nut.

- Reinstall the ring nut (3) and tighten it with a suitable tool.

E.23

NUDA 900 2012 - NUDA 900 R 2012

H10962

H10963

H10964


GENERAL PROCEDURES

Fuel pump inspectionRemove the pump as described in the relevant paragraph.

- Connect the positive pole (12V) of the power supply to the pin of the red cable in the pump connector;

Connect the negative pole of the power supply to the negative pin in the pump connector.

Never keep the pump connected to the power supply unit for more than 3 seconds in a row.

HYDRAULICDIAGRAM

OUT

REGULATOR

FINE FILTER

PUMPFUEL

PRE-FILTER

ELECTRICDIAGRAM

FUEL SYSTEM

GROUND

SIGNAL

GROUND

GROUNDFILTER

E.24

NUDA 900 2012 - NUDA 900 R 2012

H10779

1

H10924

3

H10923

2

H10782

4

GENERAL PROCEDURES


Filter box removal- Remove the fuel tank as described in the relevant paragraph.- Disconnect and remove the connector (1) of the air temperature.

- Disconnect the connector (2) of the idle air actuator (Stepper motor).

- Remove the two small tubes (3) of the idle air actuator (Stepper motor) on the throttle body.

- Loosen the two nuts (4) that fasten the chassis.

E.25

NUDA 900 2012 - NUDA 900 R 2012

H10783

5

H10784

6

H10785

7

8

9

H10786

6


GENERAL PROCEDURES

- Loosen the two front screws (5).

- Lift the filter box (6).

- Open the clamp (7) and remove the Blow-By pipe (8); remove the filter box (6).

During the reassembly, the throttle control cable (9) must pass over the pipe (8).

E.26

NUDA 900 2012 - NUDA 900 R 2012

H10787

1 2

2

4

H10788

3

H10789

5

GENERAL PROCEDURES


Throttle body removal- Remove the reservoir and the filter box as described in the relevant para-

graphs.

- Remove the throttle body (1) from the harness.

- Disconnect the connector (2) from the injectors.

- Disconnect the connector (3) of the TPS.

- Disconnect the throttle control cable (4).

- Open the two clamps (5).

- Remove the throttle body (1).

E.27

NUDA 900 2012 - NUDA 900 R 2012

H10925

1

23

4

5

6


GENERAL PROCEDURES

Exhaust system removal

Key

Silencer1. Clamp2. Exhaust valve actuator starter motor3. Lambda sensor4. Manifold5. Gasket6.

E.28

NUDA 900 2012 - NUDA 900 R 2012

H107931

2

H10794

3

34

H10795

5

6

7

H10796

8

H10797

6

GENERAL PROCEDURES


Exhaust system removal- Remove the radiator and the reservoir as described in the relevant para-

graphs.- Remove the protection (1) by loosening the screws (2).

- Loosen the nuts (3) and disconnect the cables (4) that control the exhaust valve.

- Loosen the screw (5) of the clamp (6) that fasten the silencer to the exhaust pipe (7).

- Loosen the screw (8) and remove the silencer (6).

E.29

NUDA 900 2012 - NUDA 900 R 2012

H1079810

9 9

H10799

11

H10800

12

H10801

13

H10802

10


GENERAL PROCEDURES

- Loosen the nuts (9) of the exhaust manifold (10).

- Disconnect the connector (11) of the Lambda sensor.


- Loosen the central screw (13) of the manifold support (10).- Remove the manifold (10).

E.30

NUDA 900 2012 - NUDA 900 R 2012

H1080310

H10804

14

H10805

1

H10806

2

H10807

3

GENERAL PROCEDURES


- During the reassembly, check the seals (14) for wear, replace if damaged.

Lambda sensor removal- Remove the fuel tank as described in the relevant paragraph.

- Disconnect the connector (1).


- Loosen the Lambda sensor (3) from the exhaust manifold.

E.31

NUDA 900 2012 - NUDA 900 R 2012

0,8 ÷ 0,9 mm (0,031 ÷ 0,035 in)

H10808

1

2

H10809


GENERAL PROCEDURES

Coil / Stick-Coil removal and spark plug testSpark plug electrodes gap shall be 0.8 ÷ 0.9 mm (0.031 ÷ 0.035 in).A wider gap may cause difficulties in starting the engine and overload the coil.A gap that is too narrow may cause difficulties when accelerating, when idling or poor performance at low speed.Clean off any dirt around spark plug base before removing the spark plug.It is very useful to examine the state of the spark plug just after it has been removed from the engine since the scale deposits on the plug and the colour of the insulator provide useful indications.Correct heat rating:The tip of the insulator should be dry and the colour should be light brown or grey.High heat rating:In this case, the insulator tip is dry and covered with dark deposits.Low heat rating:In this case, the spark plug has overheated and insulator tip is vitrified (glazed), white or grey in colour.

To remove spark plug, proceed as follows:- Remove the reservoir and the filter box as described in the relevant para-

graphs.- Disconnect the connector (1) from the coil / Stick-Coil (2).- Lift the coil / Stick-Coil (2) to remove it from the cylinder head.

- Loosen the spark plug with a suitable key to remove it from the cylinder head.

E.32

NUDA 900 2012 - NUDA 900 R 2012

H10810

1

2

H10811

12

3

H10812

2

3

H10813

5

4

GENERAL PROCEDURES


Horn removal- Unscrew the screw (1).- Disconnect the connector and remove the horn (2).

Radiator removal- Remove the saddle and the right-hand panel as described in the relevant

paragraphs.- Drain the coolant as indicated in the relevant paragraph.- Use suitable pliers to open the clamps (1) that fasten the pipes (2) and (3)

that connect the radiator / engine.

- Remove the two pipes (2) and (3) from the radiator.

- Open the clamp (4) and remove the pipe (5) that connects the expansion tank to the radiator.

E.33

NUDA 900 2012 - NUDA 900 R 2012

H10814

6

H10815

7

H10816

8

H10817

9


GENERAL PROCEDURES

- Loosen the screw (6).

- Cut the fan harness retaining clamp (7).

- Disconnect the connector (8) of the fan.

- Remove the radiator (9) from the right-hand side of the bike, by removing it from the special clips.

E.34

NUDA 900 2012 - NUDA 900 R 2012

H10818

10

11

H10819

13

12

H10820

1

3

2

H10821

1

2

GENERAL PROCEDURES


- During the reassembly, make sure that the pins (10) and (11) fit in the support (12) and (13) respectively.

Electric fan removal- Remove the radiator as described in the relevant paragraph.- Detach the two clips (1) that fasten the fan to the radiator (2) in the upper

part.- Loosen the lower screw (3) and remove the fan.

Gearbox lever removal- Loosen the screw (1) and remove the lever (2).

E.35

NUDA 900 2012 - NUDA 900 R 2012

H10822

1

H10823

2

5

5

4

5

3

H10824

6

7


GENERAL PROCEDURES

Battery housing removal- Remove the battery, the reservoir, the oil reservoir, and the voltage regulator,

as described in the relevant paragraphs.- Loosen and remove the upper pin (1) of the shock absorber, then tilt the

shock absorber to the rear part of the bike.

- Remove the connectors (2), (3), and (4) from the battery housing.- Cut the clamps (5) that retain the harness.

- Disconnect the connector (6) and detach the solenoid starter (7) from the support bracket.

E.36

NUDA 900 2012 - NUDA 900 R 2012

H10825

8

H10826

9

H10827

10

H10828

11

GENERAL PROCEDURES


- Loosen the screw (8) in the right-hand side, the screw (9) in the left-hand part and the two screws (10) in the rear part.

During the reassembly, position again correctly the bushings (11).

- Keep the shock absorber lifted and turn the battery housing clockwise, then remove it from the rear side.

E.37

NUDA 900 2012 - NUDA 900 R 2012

H10829

1

2

3

4

H10830

5

6

7

H10831

89


GENERAL PROCEDURES

Engine removalRemove in a sequence the following components, as described in the relevant paragraphs/chapters:- Filter box;- reservoir;- radiator with the respective pipes;- rear shock absorber and rear swinging arm;- front end (forks, yokes, handlebar, etc...);- exhaust assembly.

- Loosen the screws (1), the screw (2), unhook the spring (3) and remove the cover (4).

- Remove the la retaining pin (5) and detach the master cylinder (6) from the lever (7).

- Remove the left-hand footrest (8) with the support, by loosening the screws (9).

During the reassembly, replace the screws (9).

E.38

NUDA 900 2012 - NUDA 900 R 2012

H10832

10

H10833

11

12

H10834

13

GENERAL PROCEDURES


- Loosen the screw (10) on the left side and the screw (11) on the right side keeping the spacer (12).

- Disconnect from the engine the cable (13) of the clutch.

E.39

NUDA 900 2012 - NUDA 900 R 2012

H10835

15

17

H10836

14

16

17


GENERAL PROCEDURES

- Remove the harness (14) from the bike by cutting the retaining clamps.- Loosen the screws (15) from the left side and the screws (16) from the right

side.- Lift the chassis (17) by removing it from the engine.

E.40

NUDA 900 2012 - NUDA 900 R 2012

H10837

1

H10838

2

H10839

2

H10840

2

3

GENERAL PROCEDURES


Engine reassembly- Remove the battery support (1) from the engine by loosening the screws

(2).

- Insert the new clamps (3) in the slots and reinstall the battery support (1).

E.41

NUDA 900 2012 - NUDA 900 R 2012

H10841

6

7

6

75

6

7

5

5

4

H10842

5

4

H10843

5


GENERAL PROCEDURES

- Reinstall the chassis (4) on the engine and, from the left-hand side, screw manually the screws (5) fully home without tightening then, from the right-hand side, tighten manually the screws (6) fully home by interposing the related spacers (7).

E.42

NUDA 900 2012 - NUDA 900 R 2012

H10844

6

H10845

6

7

H10846

8

9

10

GENERAL PROCEDURES


- Install the swinging arm (8) without tightening the nut to torque (9) of the pin (10).

- Tighten the screws (5) on the left-hand side of the chassis to torque.

- Tighten the screws (6) on the right-hand side of the chassis to torque.

- Tighten the nut (9) of the swinging arm to torque.

Install in a sequence the following components, as described in the relevant paragraphs/chapters:- Left footrest;- Master cylinder with related cover;- Harness;- Exhaust assembly;- Front end;- Rear shock absorber;- radiator with relevant pipes;- reservoir;- Filter box.

F.1

NUDA 900 2012 - NUDA 900 R 2012


ENGINE SETTINGS AND ADJUSTMENTS

FSection

Refer to chapter F4 for all engine tightening torques.

F.2

NUDA 900 2012 - NUDA 900 R 2012



VALVE CLEARANCE CHECK ...................................................................... F.3Checking cylinder “1” valve clearance .......................................................... F.3Valve clearance measurement ..................................................................... F.3Checking cylinder “2” valve clearance .......................................................... F.3HALF-BALL REPLACEMENT....................................................................... F.4Locking the crankshaft.................................................................................. F.4Chain tensioner removal............................................................................... F.5Camshaft mount removal ............................................................................. F.5Camshaft removal ........................................................................................ F.5Half-ball replacement.................................................................................... F.5CAMSHAFT INSTALLATION ........................................................................ F.6Exhaust camshaft installation ....................................................................... F.6Intake camshaft installation .......................................................................... F.6Camshaft mount installation ......................................................................... F.7TIMING CHECK ........................................................................................... F.9ENGINE PHASING..................................................................................... F.10Chain tensioner removal............................................................................. F.10Camshaft mount installation ........................................................................F.11

F.3

NUDA 900 2012 - NUDA 900 R 2012

H10182

H10911

H10912



VALVE CLEARANCE CHECK

Remove the coil / spark plug cap and the head cover as described in chapter "F1".

Checking cylinder “1” valve clearance:Turn the crankshaft in the normal direct ion of engine rota-tion until cylinder “1” (“1”=> clutch side) is at power stroke TDC. At power stroke TDC, the cylinder 1 cams of both the intake and exhaust camshafts must face upwards and be at the same angle relative to the upper face of the head. In this position, check the valve clearance between cam base circle and the rocker arm.

NotE: the crankshaft cannot be locked in this position.

Valve clearance measurementUse a feeler gauge to measure valve clearance between the cam and the rocker arm.

Note down the measurements on a measurement sheet.

Technical specifications

Intake valve clearance with cold engine max. 35 °C

0,23 ÷ 0,33 mm0,0091 ÷ 0,013 in.

Exhaust valve clear-ance

with cold engine max. 35 °C

0,30 ÷ 0,41 mm0,0118 ÷ 0,0161 in.

Checking cylinder “2” valve clearance:Turn the crankshaft in the normal direct ion of engine rota-tion until cylinder “2” (“2”=> magnet side) is at power stroke TDC. At power stroke TDC, the cylinder 2 cams of both the intake and exhaust camshafts must face upwards and be at the same angle relative to the upper face of the head. In this position, check the valve clearance between cam base circle and the rocker arm.

NotE: the crankshaft cannot be locked in this position.

If the valves do not lie within the correct tolerance, correct clearance must be restored by replacing the half-balls.

F.4

NUDA 900 2012 - NUDA 900 R 2012

H10184

H10185

21

H10186

3

H10183

4



HALF-BALL REPLACEMENt

Turn the engine in the normal rotation direction until the marks IN and EX on the camshaft gears are facing each other and are positioned level with the sealing surface.

Locking the crankshaftRemove the screw (1) with the sealing ring (2).

Check if the notch (3) (arrow) on the crank arm is visible through the hole.

Fully screw down the retaining screw (4) manually; the screw must perfectly engage in the notch of the crankshaft.

F.5

NUDA 900 2012 - NUDA 900 R 2012

H10436

1

2

34

2

5

H10188

4123

H10192

32

1

H10193

1

22



Chain tensioner disassembly- Remove the screw (1) with the sealing ring (2).- Remove the spring (3) and the chain tensioner (4) from the hole.

Camshaft mount disassembly- Loosen all the nuts (2) uniformly in a diametrically opposite order and remove

them.- Remove the slider (3) with the support (4).- Refitthecamshaftmount(1).- Remove the sealing rings (5).

Camshaft removal- First lift the intake camshaft (2) and then the exhaust camshaft (1) with a

suitable tool, making sure not to damage the sealing surface.- Removethetimingchain(3)firstfromtheintakecamshaftsprocket,andthen

fromtheexhaustshaftandfixitinasuitablepointtopreventitfromfalling.- Remove the camshaft on the intake side (2).- Remove the camshaft on the exhaust side (1).

Half-ball replacement

Caution: Half balls can fall inside cylinder head oil ducts. Plug ducts with a cloth.

- Based on the valve clearance measurement, overturn the rocker arm upwards and remove the half-ball, using a magnet; then return it to its position.

- Replace the half-balls with others of a size suitable to restore correct valve clearance, referring to the values on the measurement sheet.

F.6

NUDA 900 2012 - NUDA 900 R 2012

H10191

1

2

2

H10190

21

H10189

2

1

3



- Insert the half-balls (2) slightly lubricated with engine oil between the rocker arm (1) and the valve.

Warning: Only half-balls marked with an identification number ("XXX") may

be used. Half-balls without an identification number must be elimi-nated.

- Then check that the half-balls are correctly positioned in their seats (2).

CAMSHAFt ASSEMBLY

Exhaust camshaft installation- Lubricate all support surfaces with engine oil.- Payattentiontothepositionofthecamandfittheexhaustcamshaft(1)with

the EX mark on the relevant gear level with the sealing surface (arrow).- Position the timing chain (2) on the exhaust camshaft gear.

Intake camshaft installation- Lubricate all support surfaces with engine oil.

Caution: When screwing on the bearing mount, the gears of the coolant pump

and the crankshaft must not overlap.

- Insert the intake camshaft (2).- Position the timing chain (3) on the gear of the intake camshaft (2), paying

attention to the mark IN that must be level with the sealing surface.

Caution: Check that the IN and EX marks are facing each other and that they

are level with the sealing surface.

F.7

NUDA 900 2012 - NUDA 900 R 2012

H10194

54

H10437

1

2

3

45

5

H10198

612

8

3

511

10

912 4 7



Camshaft mount assembly- Check that the sliding element (1) is not worn and replace it if necessary.- Clean the sealing surfaces.- Lubricatethenewsealingrings(2)withengineoilandfitthem.

Caution: Before fixing the mount, make sure that the axial camshaft guide is

correctly positioned (arrow).

- Lubricatethemount(3)ontheslidingsurfacewithengineoilandfitit,payingattention to the axial guides (arrows).

- Fit the sliding element support (4).- Fit all the nuts (5) and tighten them fully by hand (no tools).- Make sure that the mount (3) is positioned level on the side of the timing

chain, adjust the camshafts and the bearing bridge if necessary.

- Fully tighten all the nuts, according to the tightening sequence and the tight-ening torque.

- Mountfixingnuttighteningsequence(from1to12).

- Insert the chain tensioner, replacing the gasket (4) and activate it manually to tension the timing chain, checking that the timing is correct, then tighten the screw (5) to torque.

F.8

NUDA 900 2012 - NUDA 900 R 2012

H10196

7

H10197

89



- Remove the locking screw (7) and re-tighten the screw (8) to torque, replac-ing the gasket (9).

- Recheckvalveclearancebeforerefittingtheheadcover.

F.9

NUDA 900 2012 - NUDA 900 R 2012

H10200

12

H10199

H10201

3

H10202

4



tIMING CHECK

- Remove the coil / spark plug cap and the head cover as described in chapter "F1".

- Remove the screw (1) with the sealing ring (2).

- Check the position of the camshaft gears.- The marks EX and IN positioned on the camshaft gears must be parallel to

the sealing surface.

- Check that the notch (3) (arrow) on the crank arm is visible through the hole (marks EX and IN opposed and parallel to the surface and notch visible, indicating correct timing).

- If the notch (3) cannot be seen through the hole, carefully turn the engine until it can be seen through the hole, then fully tighten down the retaining screw (4) manually, blocking the engine at TDC; it must perfectly engage in the notch of the crankshaft.

If the marks on the camshaft gears are not opposed and parallel to the sealing surface, a collision between pistons and valves is possible.

F.10

NUDA 900 2012 - NUDA 900 R 2012

H10439

1

2

34

2

5

H10440

6

7

H10205

H10438

DABC



ENGINE PHASINGProceed as follows to rephase the engine.

- Remove the head cover as described in chapter "F1".- Lock the crankshaft as previously described.

Chain tensioner disassembly- Remove the screw (A) with the sealing ring (B).- Remove the spring (C) and the chain tensioner (D) from the hole.

- Loosen all the nuts(2) on the mount (1).- Remove the slider (3) with the support (4).- Remove the mount (1).- Remove the sealing rings (5).

- Lift the camshaft (6) and (7) from the opposite side of the distribution gears to facilitate the removal of the chain, then position the camshafts (6) and (7) so that the references EX and IN are opposed and parallel to the sealing surface.

F.11

NUDA 900 2012 - NUDA 900 R 2012

H10441

1

2

3

45

5

H10198

612

8

3

511

10

912 4 7

H10442

6

H10443

78




Caution: Before fixing the mount, make sure that the axial camshaft guide is


- Lubricatethemountslidingsurfaces(3)withengineoilandfitit,payingat-tention to the axial guides (arrows).


chain, adjust the camshafts and the bearing bridge if necessary.

- Fully tighten all the nuts, according to the tightening sequence and the tight-ening torque.


- Remove the crankshaft locking crew (6) and re-tighten the screw (7) to torque, replacing the gasket (8).


F.12

NUDA 900 2012 - NUDA 900 R 2012

H10206

9 10



- Insert the chain tensioner, replacing the gasket (9) and activate it manually to tension the timing chain, checking that the timing is correct, then tighten the screw (10) to torque.

F1.1

NUDA 900 2012 - NUDA 900 R 2012

F1


GENERAL ENGINE PROCEDURES

Section

Refer to chapter F4 for all the engine tightening torques.

F1.2

NUDA 900 2012 - NUDA 900 R 2012



ClutCh-Side leFt Cover removal/inStallation ................................F1.3Gearbox lever removal/installation ............................................................F1.3oil dipstick removal ....................................................................................F1.3Cover removal ............................................................................................F1.3Gearbox selector shaft oil seal removal/installation ..................................F1.4Clutch disengagement shaft removal .........................................................F1.4Clutch disengagement shaft oil seal removal .............................................F1.4Clutch disengagement shaft bearing removal ............................................F1.4Clutch disengagement shaft oil seal installation ........................................F1.5Clutch disengagement shaft upper bearing removal ..................................F1.5installation of both clutch disengagement shaft bearings ...........................F1.5disengagement shaft installation ...............................................................F1.5left engine crankcase cover installation ....................................................F1.6tightening sequence of the left engine crankcase cover ...........................F1.6oil dipstick installation ...............................................................................F1.6riGht enGine CrankCaSe removal/replaCement ...................F1.7Stator removal ............................................................................................F1.7Stator installation .......................................................................................F1.7right engine crankcase cover installation .................................................F1.8tightening sequence of the right engine crankcase cover .........................F1.8Flywheel and Starter motor idle Gear removal ..................F1.9Removal/installation of the freewheel from/on the flywheel........................F1.9Freewheel control gear removal .................................................................F1.9Starter motor idle gear removal/installation .............................................F1.10Installation of the flywheel with freewheel control gear ............................F1.10CrankShaFt poSition SenSor removal/ inStallation .................................................................................. F1.11Chain SproCket removal/inStallation .................................... F1.11Starter motor removal/inStallation .....................................F1.12Gear poSition SenSor removal/inStallation ........................F1.13Complete ClutCh removal/inStallation ..................................F1.14Clutch pressure plate removal .................................................................F1.17oil pump.................................................................................................F1.18oil suction pump removal/installation ......................................................F1.18oil force pump removal/installation .........................................................F1.19oil pump shaft removal.............................................................................F1.20Coolant pump removal/inStallation ........................................F1.21Coolant pump control gear removal/installation .......................................F1.24oil Sump removal/inStallation ....................................................F1.26meShoil Filter replaCement ........................................................F1.26SwinG arm Cover removal/inStallation ..................................F1.27CheCk / oil preSSure adjuStment valve replaCement .....................................................................F1.28timinG Chain removal/replaCement (enGine removed) ........................................................................F1.29heat exChanGer removal/inStallation ....................................F1.31

F1.3

NUDA 900 2012 - NUDA 900 R 2012

H10207

2

1

H10208

1

H10209

1

2

3



LeFt cLutch side coveR RemovaL/instaLLation

Warning: When installing a new crankcase cover, the bearings and the gaskets

are preassembled.

Gearbox lever removal/installation

removal:- loosen the screw (1) then remove the lever (2).

installation:- Fit the lever (2) and tighten the screw to torque (1).

oil dipstick removalremove the oil dipstick (1).

cover removalremove the screws (1).- Remove the gasket (2) and the cover (3), paying attention to the sealing ring

and the gearbox shaft.- Pay attention to the thrust washer (arrow), it may stick to the crankcase

cover.

F1.4

NUDA 900 2012 - NUDA 900 R 2012

H10210

1

H10211

12

3

H10212

1

H10215

1



Gearbox selector shaft oil seal removal/installation .- Using a screwdriver, carefully remove the oil seal from the inside diameter

(1).- Lubricate the seal lip of the new oil seal; then fit it on the cover, using an

appropriate tool.

clutch disengagement shaft removalremove the retaining ring (1).- extract the clutch disengagement shaft (2).- remove the spring (3).

clutch disengagement shaft oil seal removal- protect the housing from damage using adhesive tape (arrow).- lift the oil seal (1) using a suitable screwdriver.

clutch disengagement shaft bearing removal.- extract the lower bearing downwards (1) using a suitable punch.

F1.5

NUDA 900 2012 - NUDA 900 R 2012

H10213

1

H10214

12

3

H10216

H10217

2

1



clutch disengagement shaft oil seal installation- lubricate the oil seal lip (1) with engine oil.- install the shaft oil seal (1) with the thrust spindle.- the open side of the sealing ring is located inside.

clutch disengagement shaft upper bearing removal- protect the cover with adhesive tape.- Fit the specific puller, making sure that the jaws engage in the slit between

the bearing and the cover.- remove the bearing.

installation of both clutch disengagement shaft bearings- Lightly lubricate both bearings with engine oil.- install the needle roller bearings (1) and (2).- Drive the upper needle roller bearing (2) until it is flush with the sealing ring

housing, using a suitable tool.

disengagement shaft installation- lubricate the clutch disengagement shaft with engine oil.- insert the clutch disengagement shaft (2), being careful not to damage the

sealing ring.- push the spring (3) onto the clutch disengagement shaft and press the shaft

down, paying attention to the installation position of the spring.- install the retaining ring (1).- turn the shaft and check that the spring is hooked.

F1.6

NUDA 900 2012 - NUDA 900 R 2012

H10218

1

23

H10219

7

4

5

6

8

7

H10220

1

H10221

1112

13

16 1514 2

3

4

5

6789

1

10



Left engine crankcase cover assembly- turn the bevelled edge (1) of the clutch presser to the installation position

(see figure) between the holes (arrow).- the space washer (2) must engage on the gearbox shaft.- The main oil ducts (3) must not be dirty or obstructed.

- Fit the cover (4) with the new gasket (6) on the engine housing, paying atten-tion to the calibrated pins (7) and the sealing ring (8) of the gearbox shaft.

- Tighten the screws (5) manually.

tightening sequence of the left engine crankcase cover.- the tightening sequence for the left engine crankcase cover goes from (1)

to (16).

Warning: the indicated tightening sequence must be followed.

oil dipstick installation - Fit the oil dipstick (1).

F1.7

NUDA 900 2012 - NUDA 900 R 2012

H102233

1

2

H10224

3

2

14

H10225

1

H10226

1

2

3

4



RiGht enGine cRankcase RemovaL/RepLacement- remove the screws (1).- remove the cover (2) with the gasket (3).

stator disassemblyremove the screws (4).- remove the cable gland (3).- remove the screws (1).- release the rubber sheath from the cover and remove the stator (2) with the

cable.

stator assembly- Clean the threading in the cover.- insert the stator in the cover, the cable support (1) must be in the slit (ar-

row).

- Precisely position the stator (2) using the holes of the screws.- tighten the screws (1) to the tightening torque.- insert the rubber sheath in the cover.- Fit the cable gland (3) and the screws (4).

Warning: if the cover has been replaced, there will not be any threading as it

is created by the screw. in this case, no sealant should be used for the screws, otherwise use Loctite 243.

F1.8

NUDA 900 2012 - NUDA 900 R 2012

H10227

2

H102283

1

2

H10229

110 9

8

76

5

4

3

2

1413

12

11



Right engine crankcase cover installation- Apply a layer of sealant (Three-Bond 1209) on the sealing surface of the

rubber sheath (2).

- Clean the sealing surfaces.- Fit the new gasket (3) and the engine crankcase cover (2).- tighten the screws (1).

tightening sequence of the right engine crankcase cover- the tightening sequence for the right engine crankcase cover goes from (1)

to (14).

caution: the indicated tightening sequence must be followed.

F1.9

NUDA 900 2012 - NUDA 900 R 2012

H10230

1

2

H104511

H10444

2

3

5

4



FLyWheeL and staRteR motoR idLe GeaR RemovaL.- Remove the right crankcase and fix the engine at the top dead centre, as

described in the relevant paragraphs.- remove the screw (1) with the washer.- Heat the flywheel hub (2) to a temperature of approx. 100°C.- Remove the flywheel together with the freewheel (2) using a suitable pull-

er.- Check the tab and replace it if necessary.

Removal/installation of the freewheel from/on the flywheelremoval:- Unscrew the screws (3) and remove the flange (4) and the freewheel (5) from

the flywheel (2).

installation:- Check the condition of the freewheel (5), and replace it if it is ruined.- Refit the freewheel (5) with the relevant flange, tightening the screws to torque

(3).

Freewheel control gear removalremove the freewheel control gear (1).

F1.10

NUDA 900 2012 - NUDA 900 R 2012

H10234

1

2

H10235

1

2

H10446

1

2

34

6

7



starter motor idle gear removal/installation- Remove gears (1) and (2) and check the state of wear, refit them exactly in

the correct position, making sure that a space washer is fit above the idler gear (1).

Installation of the flywheel with freewheel control gear- Clean the collar and internal bearing of the freewheel gear (1) and lubricate

with engine oil.- Fit the freewheel gear (1) into the crankshaft.- Clean the cone of the crankshaft and of the flywheel.- Apply a thin layer of Loctite 648 on the crankshaft cone.

caution: pay attention that the freewheel bearing does not come into contact

with the Loctite.

- Fit the flywheel (2) onto the crankshaft, making sure that the groove and the key (6) are aligned and that the freewheel is set on the relevant gear (1).

- Clean both crankshaft and flywheel (2) retaining screw threading.- Tighten the screw (4) to torque with the washer (3), carefully applying a thin

layer of Loctite 648 on the screw thread.- Refit the right crankcase as indicated in the relevant paragraph.

F1.11

NUDA 900 2012 - NUDA 900 R 2012

H10237

1

2

3

H10238

12

3

4

H10239

12

3

4



cRankshaFt position sensoR RemovaL/instaLLation- remove the screw (1).- disassemble the crankshaft position sensor (2), remove the gasket (3).- Upon reassembly, replace the gasket (3) and tighten the screw (1) to the

correct tightening torque (using loctite 243).

chain spRocket RemovaL/instaLLation

removal:- remove the screw (1).- remove the bushing (2) and the tapered washer (3).- Remove the sprocket (4), using a puller if necessary, being careful not to ruin

the shaft threading.

installation:- Clean and lubricate the teeth on the main shaft and on the sprocket with

"KLUEBER 46 MR 401" grease.- Couple the sprocket (4) to the shaft, being careful to keep the side with the

thicker shoulder facing towards the engine.- insert the tapered washer (3) so that the larger diameter rests on the sprocket

and that the taper side of the bushing (2) faces the washer.- Apply a thin layer of Loctite 243 on the retaining screw (1).- tighten the screw (1) on the shaft to torque, being careful to insert the taper

side of the bushing in the hole of the tapered washer.

F1.12

NUDA 900 2012 - NUDA 900 R 2012

H10240

12

H10241

3421



staRteR motoR RemovaL/instaLLation

removal:- remove the screws (1).- Extract the starter motor, paying attention to the sealing ring (2).

installation:- Check the sealing ring (2) for damage and replace it if necessary.- Clean and lubricate the ring (2), then place it on the starter motor.- lubricate the centring tang (3) and the teeth (4).- Fit the starter motor on the crankcase and fix it with the screws (1), tightening

them to torque.

F1.13

NUDA 900 2012 - NUDA 900 R 2012

H10242

23

4

1

H10244

46

4 5

5

H10245

123



GeaR position sensoR RemovaL/instaLLation

removal:- remove the screws (1).- disassemble the gearbox potentiometer (2) with the sealing ring (3).- Check the oil seal (4) for wear; if there are leaks, replace it. to replace it, proceed as follows:- remove the oil seal (4).- insert the new oil seal (4) centring it on the shaft (5) then, using a rubber ham-

mer and a suitable punch (6), insert it in the relevant seat until the external edge of the oil seal (4) is flush with the inside of the bevelled edge.

note: make sure that the inner lip of the oil seal (4) is not damaged during installation due to the profile of the shaft.

installation:- Check the sealing ring (3), replace it if ruined, and fit it on the potentiometer

(2).- Fit the potentiometer (2) with the sealing ring, making sure that the driver

shaft engages correctly in the potentiometer during the installation phase.- insert the screws (1), tightening them to torque.

F1.14

NUDA 900 2012 - NUDA 900 R 2012

H10246

12

3

4

5

H10247

6

7

H10791

8

10

9

11

A



RemovaL/instaLLation oF the compLete cLutch

removal:- Remove the gearbox lever, the left crankcase cover and fix the engine at the

top dead centre, as described in the relevant paragraphs.- Loosen the screws (1) proceeding with diametrically opposite operations,

then remove them with the washers (2) and the springs (3).- lift the pressure plate (5).- remove the disengagement element (4).

- remove the lined plates (6) and the steel plates (7).

- insert the special tool (a) on the hub (10) to block rotation.- remove the nut (8) with the corrugated washer (9).- remove the hub (10) using the tool (a) and the spacer washer (11).

F1.15

NUDA 900 2012 - NUDA 900 R 2012

H10249

13

12

1413

H10250

1516

H10251

16

H10252

15

12



- Disassemble the clutch housing (12), paying attention to the needle roller bearings (13) and the space bushing (14).

- disassemble the control gear (15) and the thrust washer (16).

installation:- Fit the washer (16).

- insert the oil pump control gear (15) in the clutch housing (12), being careful to correctly couple the engagements of the two parts.

F1.16

NUDA 900 2012 - NUDA 900 R 2012

H10253

12

13 1413

H10255

6

7

7

H10256

6

H10792

8

10

9

11

A



- lubricate the needle roller bearings (13) with engine oil.- insert both needle roller bearings (13) with the space washer (14) in the clutch

housing (12).- Fit the clutch housing (12) all the way down, paying attention to the oil pump

gears.

- Clean the tapered teeth on the primary shaft and on the clutch hub (10) and lubricate them.

- Fit the spacer washer (11) and the clutch hub (10) all the way down.- Clean the threading on the primary shaft.

caution: the clutch shaft oil nozzle shall not be dirtied with threadlocker.

- insert the special tool (a) on the hub (10) to block rotation.- Fit the corrugated washer (9) and the nut (8) and tighten to torque.- remove the special tool (a).

- lubricate the lined plates (6) with engine oil.- Insert first the steel plate (7) with the notch (arrow) with the sharp edge facing

inwards; then insert a lined plate (6) with narrow drive teeth (13 mm).

important: Fit the steel plates with their sharp edge inwards.

- the clutch plate pack includes nine friction plates, two with narrow drivers and seven with wide ones.

- alternate the steel plates with the lined plates with the wide drive teeth (14 mm).

- at the end, insert a lined plate (6) with narrow drive teeth (13 mm) in an offset position with respect to the others.

F1.17

NUDA 900 2012 - NUDA 900 R 2012

H10257

4

1

23

5

H10258

1

H10259

2

H102601 2



- Insert the actuator pin (4) in the pressure plate (5) and fit the pressure plate (5).

- Insert the flanged bushings (2) on the springs (3) and fit the springs on the pressure plate (5).

- Tighten the screws (1) to torque in a diametrically opposite order.

Refit the other parts that were previously removed as described in the relevant paragraph.

clutch pressure plate disassembly- disassemble the pressure plate (1) as described in the paragraph "Clutch

disassembly".

- position the pressure plate with the upper side facing downwards.- Heat the pressure plate to approx. 80°C.- remove the disengagement bearing (2) using a suitable puller.- Clean the housing of the support.- lubricate the clutch disengagement bearing with engine oil.- Heat the pressure plate to approx. 80°C.

- Fit the clutch disengagement bearing (2) using a suitable tool.

important: the writing on the bearing must face towards the engine (visible

during installation).

- Refit the pressure plate (1) as described in the paragraph "Clutch disas-sembly".

F1.18

NUDA 900 2012 - NUDA 900 R 2012

H10261

12

3

H10262

1

2

3

H10263

1

2

3

4

5

H10264

123



oiL pump

oil suction pump removal/installation

removal:- remove the sprocket casing as described in the relevant paragraph.- remove the screws (1).- disassemble the cover (2) with the gasket (3).

- disassemble the rotor (2) with the rotating piston (1), extract the pin (3) from the shaft.

- Check the condition of the pin (3) and replace it if necessary.

installation:- Clean all components prior to installation and lubricate them with engine

oil.- insert the pin (3) in the shaft.- place the rotating piston (1) on the shaft with the mark (4) facing outwards,

paying attention to the correct positioning of the pin (3).- Fit the rotor (2) with the mark (5) facing outwards, so that it coincides with

the mark (4) on the rotating piston (1).

- Clean the sealing surfaces.- Lightly lubricate the new gasket (3) with engine oil and place it on the cover

(2).- Fit the cover (2) tightening the screws (1) to torque.

- Refit the other parts as described in the relevant paragraphs.

F1.19

NUDA 900 2012 - NUDA 900 R 2012

H10265

3

21

4

H10266

6

5

H10267

87

9



oil force pump removal/installation - remove the complete clutch as described in the relevant paragraph.

removal:- disassemble the retaining ring (4) and the washer (3).- disassemble the gear (2).- disassemble the drive pin (1).

- remove the screws (5).- remove the cover (6).

- disassemble the rotating piston (7) and the rotor (8), extract the pin (9) from the shaft.

- Check the condition of the pin (9) and replace it if necessary.

F1.20

NUDA 900 2012 - NUDA 900 R 2012

H10268

87

9

10

11

H10269

6

7

12

H10270

12

34

H10271

1



installation:- Clean all components prior to installation and lubricate them with engine

oil.- insert the pin (9) in the shaft.- place the rotating piston (7) on the shaft with the mark (10) facing outwards,

paying attention to the correct positioning of the pin (9).- Fit the rotor (8) with the mark (11) facing outwards, so that it coincides with

the mark (10) on the rotating piston (7).

- Clean the sealing surfaces.- Fit the cover (6), paying attention to the centring pin (12).- tighten the screws (5) to torque.

- Check the drive pin (1) for wear and replace it if it is ruined.- insert the drive pin (1) in the shaft.- Fit the gear (2), making sure it engages on the drive pin.- Fit the washer (3).- Fit the new retaining ring (4).

- Refit the clutch as described in the relevant paragraph.

oil pump shaft disassemblyremove the force pump and the oil suction pump as described in the relevant

paragraphs.- drain the oil as described in the relevant paragraph.- disassemble the oil pump shaft (1), check the shaft (1) and oil seals for wear

and replace them if necessary.- Refit everything proceeding in reverse order as described in the relevant

paragraph.

F1.21

NUDA 900 2012 - NUDA 900 R 2012

H10272

1

2

3

4

6

55

H10273

7

9

8

4

H10275

12

11

H10452

10



cooLant pump RemovaL/instaLLation

removal:- drain the coolant as indicated in the relevant paragraph.- open the pipe clamps (1) using a suitable tool and disconnect the pipes (2)

from the radiator (3) and from the pump cover (4).- open the pipe clamps (5) using a suitable tool and disconnect the pipes

(6).

- Unscrew the screws (7) paying attention to the washer (8).- remove the pump cover (4) with the gasket (9).

- use a suitable tool to disassemble the impeller (10) (right hand threading).

- unscrew the screw (11).- Remove the pump body (12) using a suitable tool.

F1.22

NUDA 900 2012 - NUDA 900 R 2012

H10276

13

H10277

14

H10278

1317

16

15

18

H10279

19



- remove the control gear (13).

- Check that the hole (14) in the engine cylinder head is not blocked and clean it if necessary.

- Clean the seat of the pump in the engine cylinder head.

- lubricate the washers (15), the bearing (16) and the pin (17) with engine oil.

- lubricate the pump shaft through the hole (18) with engine oil.- Make sure the control gear (13) is correctly positioned on the shaft.- the pin (17) must engage in the control gear (13).

- Seal the pump support surface (19) using Three-Bond 1209 sealant.

F1.23

NUDA 900 2012 - NUDA 900 R 2012

H1028111

12

H10283

8

7

9

46 6

H10280

21

20

a

H10453

1



- lubricate the sealing rings (20) with KLUEBER 46 MR 401 (replace them if necessary), making sure the hole (21) is not blocked.

- Clean the hole (21) if necessary.- do not clean the hole with compressed air.- Apply a layer of Three-Bond 1209 on the contact surface of the pump body

(a).

- Insert the pump body (12) with the driving wheel in the engine head, making sure the teeth engage with the gear of the camshaft.

- Push the pump (12) all the way down with a suitable pipe bushing, applying pressure only on the outer edge of the pump.

- tighten the screw (11) to torque.

- Fit the impeller (1), screwing it onto the pump shaft.

- replace the gasket (9) and insert it in the water pump cover (4).- Fix the cooling ducts (6) to the cover (4).- Replace the washer (8) and carry out the installation tightening the screws

(7), paying attention to the specified tightening sequence.

F1.24

NUDA 900 2012 - NUDA 900 R 2012

H10284

5

21

3 4

H10285

5

5

1

2

H10286

1

2 3

H10287

6 2

4

5

7



- Fully tighten the screws based on the sequence (1) - (5).

- Fix the pipe clamps (5) carefully checking that the tabs of the clamps are facing towards the rear.

- Fit the pipes (2) on the radiator and on the pump and fix them with the clamps (1).

- Fill with coolant as described in the relevant paragraph.

coolant pump control gear removal/installation

removal:- remove the coolant pump.- Remove the head cover, fix the engine at the top dead centre, remove the

chain tensioner and remove the camshaft bearing mount as described in the relevant paragraphs.

- First lift the intake camshaft (2) and then the exhaust camshaft (1) with a suitable tool, making sure not to damage the sealing surface.

- Remove the timing chain (3) first from the intake camshaft sprocket (2), and then from the exhaust shaft (1) and fix it in a suitable point to prevent it from falling.

- remove the intake camshaft (2).

- remove the screw (4) (left-hand threading) and the washer (5), blocking the shaft (2) from the socket (6).

- remove the control gear (7).

F1.25

NUDA 900 2012 - NUDA 900 R 2012

H10288

2

1

H10289

5

4

76



- replace the control gear (7) on the camshaft with a new part.- replace the water pump as described in the relevant paragraph.

installation:- Clean the threading and the washer (5).- Clean the contact surface and fit the driving wheel (7).- tighten the screw (4) (left-hand threading) and the washer (5) to torque,

blocking the shaft from the socket (6).

Reassembly:- Refit the coolant pump and the camshafts as described in the relevant para-

graphs.- Refit the other components previously removed as described in the relevant

paragraphs.

F1.26

NUDA 900 2012 - NUDA 900 R 2012

H10429

1

2

H10430

9 8

2

14

13

3

4

12

8

7

9

1

10

11

H10298

2

1

3

4

4 4

4

H10299

1

3

2

4

4 4

4



oiL sump RemovaL/instaLLation

removal:- drain the oil from the engine as described in the relevant paragraph.- remove the screws (1) and the oil sump (2).

installation:- Clean the sealing surfaces.- Fit the oil sump (2) paying attention to the centring pins.- tighten the screws (1) to torque as described in the installation sequence

(1) - (14).

mesh oiL FiLteR RepLacement

- disassemble the oil sump as described in the relevant paragraph.

removal:- release the oil manifold prongs (3) from the retainers (4).- Remove the manifold (3), the gasket (2) and the mesh filter (1).- Clean or replace the mesh filter (1).

installation:- Check the oil manifold gasket (2) and replace it if necessary.- The manifold must be precisely inserted in the cover of the swing arm hous-

ing, as any leaks cause a reduction in oil delivery.- Check the prongs on the manifold (3), and if damaged or broken replace the

manifold.- Fit the filter (1) on the manifold (3), paying attention to the installation posi-

tion.- The circular rib (arrow) on the filter must face towards the engine.- Fit the oil manifold (3) with the gasket (2) on the engine, making sure all

prongs engage in the support (4).- Refit the oil sump as described in the relevant paragraph.

F1.27

NUDA 900 2012 - NUDA 900 R 2012

H10293

3

4

5

H10294

3

4

5

6

H10431

12

H10431

12



sWinG aRm coveR RemovaL/instaLLation

removal:- disassemble the oil sump as described in the relevant paragraph.- remove the screws (1) and the gasket (2).

- remove the screws (3).- remove the cover (4).- remove the gasket (5).

installation:- Clean the threading and the sealing surfaces.

caution: the pin of the compensation connecting rod axis could detach. during installation, make sure that the pin of the compensation

connecting rod axis is correctly fixed in its seat.

- Check the correct positioning of the pin (6).- Fit the gasket (5) and the cover (4) on the crankcase.- Manually tighten the screws (3) (Loctite 243).

- Fit the gasket (2) and manually tighten the screws (1) (Loctite 243).

F1.28

NUDA 900 2012 - NUDA 900 R 2012

H10447

1

2

H10448

1

2

H10432

710139

6

5

4 2

11 8



- tighten the screws to torque, referring to the installation sequence (from 1 to 11).

- Refit the oil sump as described in the relevant paragraph.

oiL pRessuRe adjustment vaLve check/RepLacement

removal:- remove the swing arm cover as described in the relevant paragraph.- disassemble the oil pressure valve (1) with the spring (2).- Check the condition of the valve.- insert the valve in the cover and activate it a few times to check spring elas-

ticity.- If the valve does not function properly, it must be replaced.

- Check that the seat of the oil delivery valve is not dirty, and clean it if neces-sary.

- Clean the valve seat.

installation:- insert the oil pressure valve (1) together with the spring (2) in the cover and

check its operation manually.- Refit the swing arm cover as described in the relevant paragraph.

F1.29

NUDA 900 2012 - NUDA 900 R 2012

H10300

1

2

H10301

3



Timing chain removal/replacemenT (engine removed)

Perform the following operations, as described in the relevant paragraphs, before disassembling the timing chain:- Drain the engine oil.- Removetheoilfilter.- Remove the starter motor.- Fix the engine to the engine mount.- Remove the spark plug recess ignition coil .- Remove the head cover.- Check valve clearance.- Fix the engine on the top dead centre of the ignition.- Remove the camshaft bearing mount.- Remove the chain tensioner.- Remove both camshafts.- Remove the timing chain slider.- Remove the chain sprocket.- Remove the oil sump.- Remove the swing arm housing cover.- Remove the right engine crankcase cover.- Release the fastening at the top dead centre.- Remove the gearbox lever.- Remove the left engine crankcase cover.- Remove the selector shaft.- Remove the lower part of the crankcase.- Remove the gearbox output shaft oil seal.

Removal:- Mark the installation position of the two caps (2) before removing them.- Upon reassembly, the caps must be inverted.- Remove the screws (1) and the two caps (2).

- Move the crankshaft (3) upwards, creating a slight rotary movement and support it at the base with a suitable tool.

F1.30

NUDA 900 2012 - NUDA 900 R 2012

H10302

4

H10303

5

6

H10304

4

H10305

37



- if the timing chain (4) is reused, mark the rotation direction before removing it.

- take the timing chain (4) off the sprocket and remove it.

- remove the screw (5).- extract the chain tensioner slider (6) towards the bottom.- Replace the chain tensioner slider, refitting it in the opposite direction, tight-

ening the screw (5) to torque.

installation:- insert the timing chain (4) in the relevant recess and place it on the crankshaft

sprocket.

- Before lowering the crankshaft (3) lubricate all supporting points with engine oil.

- Carefully remove the support tool (7).- Carefully insert the crankshaft (3) on the split bearings.

F1.31

NUDA 900 2012 - NUDA 900 R 2012

H10306

1

2

H10307

76

58

4

1

23

H10309

1

2 3

H10310

1

2 3



- Fit the caps (2), paying attention to the correct positioning of the centring pins and the installation position marks.

note: the caps (2) must not be inverted.

- Replace the screws (1) and tighten them manually.- tighten the screws (1) to torque, referring to the installation sequence (from

1 to 8)

- Refit the previously removed parts as described in the relevant para-graphs.

heat exchanGeR RemovaL/instaLLation

removal:

Warning: during the installation/removal operations, make sure not to mix

liquids from different circuits.

- drain the coolant and the oil as described in the relevant paragraphs.- remove the screws (1).- Refit the heat exchanger (2).- remove the gasket (3).

installation:- Fit the new gasket (3).- Fit the heat exchanger (2).- tighten the screws (1) to torque.- Refill with coolant and oil as described in the relevant paragraphs.

F2.1

NUDA 900 2012 - NUDA 900 R 2012


CYLINDER HEAD REMOVAL/DISASSEMBLY

F2Section


F2.2

NUDA 900 2012 - NUDA 900 R 2012



Spark plug recess ignition coil removal ......................................................F2.3Head cover removal/installation .................................................................F2.3Chain tensioner removal/installation...........................................................F2.4Locking the crankshaft................................................................................F2.5Crankshaft locking screw removal ..............................................................F2.5Camshaft mount removal ...........................................................................F2.6Camshaft mount installation .......................................................................F2.6Camshaft removal/replacement..................................................................F2.8Timing chain slider replacement ...............................................................F2.10Rocker arm removal/installation or replacement ...................................... F2.11Cylinder head removal/installation - replacement of cylinder head gasket .................................................................................................F2.12Cylinder head disassembly.......................................................................F2.13Valve removal ...........................................................................................F2.13

F2.3

NUDA 900 2012 - NUDA 900 R 2012

H10311

1

H10449

1

2

3

4

H10313



Removal of the ignition coil from the spark plug recess- Remove the ignition coil from the spark plug recess (1).

Cylinder head cover removal/installation

Removal:- Remove the screws (1).- Remove the head cover (2) with the gaskets (3) and (4).

Installation:- Apply Three-Bond 1209 sealant on the new gasket in the indicated point

(arrows).

F2.4

NUDA 900 2012 - NUDA 900 R 2012

H10314

6

1

H103155

25

2

4

5

H10316

1234

H10317

1234



- Replace the rubber bushings (6) and the screws (1).

- Clean the sealing surfaces and the gaskets.- Check and if necessary replace the sealing ring (5).- Position the head cover (2) paying attention to the breather opening (ar-

row).- The opening (arrow) rests on the sealing ring (5).- Tighten the screws (4) to torque in a diametrically opposite order.

Chain tensioner removal/installation

Removal:- Remove the screw (1) with the sealing ring (2).- Remove the spring (3) and the chain tensioner (4) from the hole.

Installation:- Insert the chain tensioner (4) and the spring (3) in the hole.- Replace the sealing ring (2) and tighten the screw (1) to torque.

F2.5

NUDA 900 2012 - NUDA 900 R 2012

H10318

H10319

12

H10320

3

H10321

4



Locking the crankshaft- Remove the head cover as described in the relevant paragraph.- Rotate the engine in the normal direction of rotation until the marks IN and

EX on the camshaft gears are facing each other and are level with the seal-ing surface.

- Remove the screw (1) with the sealing ring (2).

- Check if the notch (3) (arrow) on the crank arm is visible through the hole.

- Manually tighten the retaining screw (4) fully down; it must perfectly engage in the notch of the crankshaft.

Crankshaft locking screw removal- Remove the screw (4) and tighten the screw (1) to torque after replacing the

gasket (2).- Refittheheadcoverasdescribedintherelevantparagraph.

F2.6

NUDA 900 2012 - NUDA 900 R 2012

H10436

1

2

34

2

5

H10194

54

H10437

1

2

3

45

5

H10198

612

8

3

511

10

912 4 7



Camshaft mount disassembly- Loosen all the nuts (2) uniformly in a diametrically opposite order and remove

them.- Remove the slider (3) with the support (4).- Remove the camshaft mount (1).- Remove the sealing rings (5).


Caution: Beforefixingthemount,makesurethattheaxialcamshaftguideis


- Lubricatethemount(3)ontheslidingsurfacewithengineoilandfitit,payingattention to the axial guides (arrows).


chain,adjustthecamshaftsandthebearingbridgeifnecessary.

- Fullytightenallthenuts,accordingtothetighteningsequenceandthetight-ening torque.


- Insertthechaintensioner,replacingthegasket(4)andactivateitmanuallytotensionthetimingchain,checkingthatthetimingiscorrect,thentightenthe screw (5) to torque.

F2.7

NUDA 900 2012 - NUDA 900 R 2012

H10196

7

H10197

89



- Remove the crankshaft locking screw (7) and re-tighten the screw (8) to torque(seechapter“F4”),replacingthegasket(9).


F2.8

NUDA 900 2012 - NUDA 900 R 2012

H10325

1

2 3

H103264

2 35

H10328

7

6

8

9

H10327

5

41011



Camshaft removal/replacement

Removal:- FixtheengineattheTDC,removethecamshaftmountandremovethechain

tensioner as described in the relevant paragraphs.- First lift the intake camshaft (2) and then the exhaust camshaft (1) with a

suitabletool,makingsurenottodamagethesealingsurface.- Removethetimingchain(3)firstfromtheintakecamshaftsprocket,andthen

fromtheexhaustshaftandfixitinasuitablepointtopreventitfromfalling.- Remove the camshaft on the intake side (2).- Remove the camshaft on the exhaust side (1).

- Ifthecamshaftsmustbereplaced,proceedasfollows:- Removethescrew(4), lockingthecamshaft(2)and(3)bymeansof the

socket.- Remove the chain gear (5).

- Remove the water pump control gear (6) by unscrewing the screw (7) (left-hand threading)and remove thewasher (8), lock the intakeshaft (2)bymeans of the socket (9).

Installation:- Clean the threading.- Fit the chain gear (5) on both camshafts so that the pin (10) catches in the

hole (11).- Tighten the screw (4).

F2.9

NUDA 900 2012 - NUDA 900 R 2012

H10329

7

6

8

H10330

1 3

H10331

2

1

3



- Clean the threading and the washer (8) of the intake camshaft (2).- Cleanthecontactsurfaceandfitthedrivingwheel(6).- Tighten the screw (7) (left-hand threading) with the washer (8) locking the

shaft with the socket (9).

- Lubricate all support surfaces with engine oil.- Payattentiontothepositionofthecamandfittheexhaustcamshaft(1)with

the EX mark on the relevant gear level with the sealing surface (arrow).- Place the timing chain (3) on the inner side of the exhaust camshaft gear

(1).

- Lubricate all support surfaces with engine oil.

- Inserttheintakesidecamshaft(2),placethetimingchain(3)ontheinnerside of the gear.

- Fitthetimingchain(3)ontheexhaustsidecamshaft(1),payingattentiontothe EX mark.

- The EX mark must be level with the sealing surface.- Fitthetimingchain(3)ontheintakesidecamshaft(2),payingattentionto

the IN mark.- The IN mark must be level with the sealing surface.- Fit the chain tensioner and activate it manually to tension the timing chain.- Check the marks on the camshaft gears.- The IN and EX marks must face each other and must be level with the sealing

surface.

- Refitthecamshaftmountasdescribedintherelevantparagraph(withoutfittingtheheadcover).

- Check the valve clearance and the timing as described in chapter "F".- Ifvalveclearanceandtimingarecorrect,refittheheadcover.

F2.10

NUDA 900 2012 - NUDA 900 R 2012

H10332

2

1

1

H10334

3

H10333

2

1

1



Timing chain slider replacement- Removethechaintensioner,thecamshaftsandtheclutchcoverasdescribed

in the relevant paragraphs.- Unscrew the screw (1).- Remove the mobile chain tensioner slider (2) towards the top.

- Removethefixedslider(3)ofthetimingchaintowardsthetop.

- Check the chain sliders for wear and replace them if worn.- Insert the slider (2).- Clean the threading.- Tighten the screw (1) to torque with Loctite 243.- Insert the slider (3).- Refitthecamshafts,thechaintensionerandtheclutchcoverasdescribed

in the relevant paragraphs.

F2.11

NUDA 900 2012 - NUDA 900 R 2012

H10335

2

1

2

H10336

1

3

4

H10337

1

3

4



Rocker arm removal/installation or replacement

Removal:- Remove the camshafts as described in the relevant paragraph.

Caution: The half-balls can fall inside the cylinder head oil ducts. Plug ducts

with a cloth.

- Overturn the rocker arms (1) upward and remove the half balls (2) using a magnet.

- Return the half-balls (2) to their seats in an orderly manner.

- Remove the safety clips (3).- Extract the rocker arms (1) from the pins (4).

Installation:- Lubricate the pins (4) of the rocker arms (1) with engine oil.

Caution: Replace the safety clips (3).

- Fittherockerarms(1)onthepins(4),thenfitthesafetyclips(3).- The rounded side of the safety clips must face the rocker arm.

- Refitthecamshaftsasdescribedintherelevantparagraph.

F2.12

NUDA 900 2012 - NUDA 900 R 2012

H10338

12

3

4

H10339

23

1

4

5

5

H103406

23

51

4



Cylinder head removal/installation - replacement of cylinder head gasket- Remove thecamshafts, timingchainslidersasdescribed in the relevant

paragraphs.

Removal:- Unscrew the screws (1).- Unscrew the screws (2).- Removethecylinderhead(3),releasethegaskettobereplaced(4)tapping

it lightly if needed.

Installation:- Cleancylinderheadandenginecrankcasesealingsurfacesandfitanew

gasket (4).- Fitthehead(3),payingattentiontothehead-crankcasecouplingbymeans

of the centring pins (5).- Tighten the screws (1) and (2) manually.

Tighten the screws (2) according to the indicated order and according to what isspecifiedintherelevantchapter.

- Tightenthescrews(1)accordingtowhatisspecifiedintherelevantchap-ter.

NoTE: Always replace the screws (2) and the gasket (4) during reassem-bly.

F2.13

NUDA 900 2012 - NUDA 900 R 2012

H103423

2

1

H10343

4

H10344

H10345



Cylinder head disassembly

Caution: Iftheheadisreplaced,alsothecamshaftmountmustbereplaced.

The spare head is supplied together with the mount.

- Remove the cylinder head as described in the relevant paragraph.- Remove the cooling pump as described in the relevant paragraph.- Remove the rocker arms as described in the relevant paragraph.

Disassembly:- Loosen the clamps (1) and remove the intake coupling (2).- Remove the temperature sensor (3).

- Remove the rocker arm pins (4).

Valve removal- Place a suitable protection to the side under the cylinder head so that the

valves do not rest on the work bench.- Loosenthevalves,gentlytappingontheuppersection.

F2.14

NUDA 900 2012 - NUDA 900 R 2012

H10346

6

7

98

5

6

H10347

10

9

H10348

67

98

5

6

H10349

4



- Usingasuitabletool,pre-loadthevalvespring(5),removethevalvecollets(6) and then release the valve spring.

- Remove the upper valve spring retainer (7) and the valve spring (5)- Remove the bottom valve spring retainer (8).- Remove the valves (9).- Removethevalvestemgaskets,usingasuitabletool.

Installation:- Lubricate the valve stems with engine oil and insert the valves (9) in the

head.- Insertthegasket(10)onthevalvestem,beingcarefulnottoruinthesealing

lip.- Usingasuitabletool,pushthegasket(10)initsseatinthecylinderhead.- Repeat the operation also for the other three valves.

- Fit the lower valve spring retainer (8).- Fit the valve spring (5) and the upper valve spring retainer (7).- Withthevalveclosed,useasuitabletooltopre-loadthevalvespring(5).- Fit the valve (5) collets (6) and release the spring again.- Then check the correct position of the valve collets (6).

- Fit the rocker arm pins (4).

F2.15

NUDA 900 2012 - NUDA 900 R 2012

H10350

2

13



- Fittheintakecouplings(2)andfixthemwiththeclamps(1),beingcarefultoposition their hooks downwards.

- Fit the temperature sensor (3).- Refittherockerarms,thecoolingpumpandtheheadasdescribedinthe

relevant paragraphs.

F3.1

NUDA 900 2012 - NUDA 900 R 2012

F3


CRANKCASE DISASSEMBLY

Section


F3.2

NUDA 900 2012 - NUDA 900 R 2012



CrankCaSe diSaSSembly ...................................................................F3.3Gearbox removal ........................................................................................F3.4Gearbox output shaft disassembly .............................................................F3.5Gearbox input shaft disassembly ...............................................................F3.7Shit drum star removal ...............................................................................F3.8ratchet removal .........................................................................................F3.8Gearbox fork removal .................................................................................F3.8Gear selection drum removal .....................................................................F3.9Gear selection drum disassembly ..............................................................F3.9CrankSHaFT remOVal .......................................................................F3.10Compensation arm removal .....................................................................F3.10Connecting rod cap removal.....................................................................F3.10main bearing cap removal ........................................................................ F3.11Crankshaft removal .................................................................................. F3.11main split bearing removal........................................................................F3.12Chain tensioner slider removal .................................................................F3.12Piston removal ..........................................................................................F3.12Piston ring removal ...................................................................................F3.13Piston ring installation...............................................................................F3.13Piston installation......................................................................................F3.14Piston installation with connecting rod......................................................F3.14Chain tensioner slider installation .............................................................F3.15main split bearing installation ...................................................................F3.15Crankshaft installation ..............................................................................F3.15main bearing cap installation ....................................................................F3.16Connecting rod cap installation ................................................................F3.16Compensation arm installation .................................................................F3.17Gear selector drum installation .................................................................F3.18installation of the 5th/6a gear engagement fork .........................................F3.18installation of the 1st/3rd and 2nd/4th gear engagement fork........................F3.18ratchet installation ...................................................................................F3.18Star-shaped stop element installation ......................................................F3.19reassembly of the gearbox input and output shaft .................................F3.19installation of the lower part of the engine crankcase half........................F3.20Fixing the compensation arm ...................................................................F3.22Fixing the crankcase halves .....................................................................F3.22Gearbox output shaft oil seal installation ..................................................F3.23

F3.3

NUDA 900 2012 - NUDA 900 R 2012

H10351

1

H10352

2

2



CRankCase disassemblyWith the engine removed from motorcycle, remove the following components before disassembling the crankcase.- remove the cylinder head.- remove the heat exchanger.- remove the starter motor.- Removetheoilfilter.- remove the oil sump.- Removethefloatingarmcasing.- remove the clutch cover.- remove the complete clutch.- remove the ignition cover.- remove the complete ignition.- remove the complete oil pump (intake/delivery).- remove the gearbox potentiometer.- remove the sprocket.- remove the crankshaft sensor.

refer to the relevant paragraphs/chapters for the removal operations.

- Fit the engine on a suitable support in order to make the removal operations easy and safe.

- From the left side, remove the gearbox shaft (1).

- Turn the engine and remove the screws (2).

F3.4

NUDA 900 2012 - NUDA 900 R 2012

H10353

4

3

5

H10354

7 6

H10355

8

9

H10356

9

8



- Turn the lower part of the engine upwards.- remove the safety pin (3).- Using a suitable puller, remove the pin (4) of the compensation arm (5).- rotate the compensation arm (5) upward.

- remove the screws (6).- remove the lower crankcase half (7) towards the top, making sure the split

bearings do not fall out.

- Slightly lift the gearbox output shaft (8) and remove the oil seal (9).

Gearbox removalremove the gearbox output shaft (8) and input shaft (9).

F3.5

NUDA 900 2012 - NUDA 900 R 2012

H10357

2

1

H10358

8

765

43

H1035910

9 1113

1517

12 1416

H10360

18



Gearbox output shaft disassemblyremove the retaining ring (1).- remove the bearing (2), being careful not to damage the gear and the bear-

ing seat.

- extract the washer (3).- extract the idle wheel (4).- extract the needle roller bearing (5).- extract the washer (6).- extract the idle wheel (7).- remove the retaining ring (8).

- extract the idle wheel (9) and (10).

Caution: during the removal operations, be careful not to ruin the needle

roller bearings.

- remove the needle roller bearings (11) and (12), being careful not to damage the rollers.

- remove the retaining ring (13).- extract the idle wheel (14).- remove the retaining ring (15).- extract the idle wheel (16).- remove the needle roller bearing (17), being careful not to damage the roll-

ers.- remove the bearing (18) with a suitable tool, being careful not to damage

the gear and the bearing seat.

F3.6

NUDA 900 2012 - NUDA 900 R 2012

H10361

1315

910

11 12 14 16

17

H10362

8

3 45 6 7

H10363

12

18



Caution: during operation, the gear pairs slide towards each other. if just one

coupling gear is replaced, the load bearing capacity on gears may become significantly worse.

Replace the paired gears, but one at a time!

- all components must be checked before being installed. if imperfections are found, replace them.

- Clean the supporting points and lubricate them with engine oil,- Fit the needle roller bearing (17), being careful not to damage the rollers.- Fit the idle wheel (16) with the lubrication grooves facing forward.- Fit a new retaining ring (15) in its seat.- Clean the sliding seat and the inner toothing and lubricate with engine oil.- insert the idle wheel (14) with the groove facing outwards.- Fit a new retaining ring (13) in its seat.- Clean the supporting points and lubricate them with engine oil.- Fit the needle roller bearings (11) and (12), being careful not to damage the

rollers.- Fit the idle wheel (10) with the engagement gear gripping grooves facing

forward.- Fit the idle wheel (9) with the engagement gear gripping grooves facing

outwards.

- Fit a new retaining ring (8) in its seat.- insert the idle wheel (7) with the groove facing forward.- Oil the washer (6) and insert it.- Clean the supporting points and lubricate them with engine oil.- insert the needle roller bearing (5), being careful not to damage the rollers.- Fit the idle wheel (4) with the large edge (arrow) facing inwards.- Oil the washer (3) and insert it in its seat.- Checkthetwobearingsbeforefittingthem.- Clean and lubricate the bearing seats.

- Fitthebearing(2)andthebearing(18)usingaspecifictoolandbecarefulnot to damage the gear or the bearing seat.

- Fit a new retaining ring (1) in its seat.

F3.7

NUDA 900 2012 - NUDA 900 R 2012

H10364

21

H10365

34

56

789

10

H10366

34

56

789

10



Gearbox input shaft disassemblyremove the bearings (1) and (2) with a suitable tool, being careful not to

damage the gear and the bearing seat.

- extract the idle wheel (3).- extract the idle wheel (4).- remove the needle roller bearing (5).- remove the retaining ring (6).- extract the idle wheel (7).- remove the retaining ring (8).- extract the washer (9) and the idle wheel (10).

Caution: during operation, the gear pairs slide towards each other. if just one

coupling gear is replaced, the load bearing capacity on gears may become significantly worse.

Replace the paired gears, but one at a time!

- all components must be checked before being installed. if imperfections are found, replace them.

- Clean the supporting points and lubricate them with engine oil.- insert the idle wheel (10), the toothed engagements must face the sliding

seat.- insert the ring (9).- Fit a new retaining ring (8) in its seat.- Clean the sliding seat and lubricate it with engine oil.- Insertfirsttheidlewheel(7)withthesmallgear.- Fit a new retaining ring (6) in its seat.- insert the needle roller bearing (5), being careful not to damage the rollers.- insert the idle wheel (4) with the toothed engagements facing inwards.- Clean and lubricate the sliding seats.- insert the idle wheel (3) with the projecting part facing inwards.- Checkthetwobearingsbeforefittingthem.- Clean and lubricate the bearing seats.

F3.8

NUDA 900 2012 - NUDA 900 R 2012

H10367

1

2

H10368

1

3

2

H1036912

34

H10370

1

2

3



- Fit the bearings (1) and (2) with a suitable tool, being careful not to damage the gear and the bearing seat.

shift drum star removalremove the shift drum star as follows:- Plug the openings in the crankcase with rags.- Turn the star (3) one notch from the neutral position (arrow).- Unscrew the screw (2).- move the ratchet (1) and remove the star (3).

Ratchet removalremove the ratchet (2) by unscrewing the screw (1) and removing the bush-

ing (3) and the spring (4).

Gearbox fork removalremove the safety pin (1).- remove the fork pin (2).- remove the engagement forks (3) of the 1st/3rd and 2nd/4th gear.

F3.9

NUDA 900 2012 - NUDA 900 R 2012

H10371

4

5

H103721

2

H10373

21

H10374

4

3



- remove the fork pin (4).- remove the engagement fork (5) of the 5th/6th gear.

Gear selection drum removalremove the screw (1).- remove the drum (2) from the lower crankcase half.

Gear selection drum disassemblyremoval:- Fit the original screw (1) to protect the threading in the selector drum.- remove the external bearing of the selector drum (2) using a suitable

puller.

- Heat the drum in the area of the internal bearing to approx. 80°C.- rotate the drum (3) to let the internal bearing (4) fall out of it.

F3.10

NUDA 900 2012 - NUDA 900 R 2012

H10375

4

H10376

1

H103771

23

34

H10378

1

2



installation:- Heat the drum in the area of the internal bearing to approx. 80°C.- Fit the inner bearing (4) using a press, making sure that the bearing rests

correctly on its seat.- Theexternaledgeofthebearing(4)mushbeflushwiththeexternaledgeof

the drum.

- Heat the external bearing (1) to approx. 80°C.- Fit the external bearing (1) on the drum, making sure that the bearing rests

correctly on the relevant drum seat.

CRanksHaFT RemOValCompensation arm removal- move the compensation arm backwards and remove the screws (1).- remove the connecting rod caps (2) and the balancing connecting rod (4).

Caution: The connecting rod and the compensation arm must not be disas-

sembled.

- remove the split bearings (3).

Connecting rod cap removal- mark the connecting rod caps for the respective connecting rods.- The marks must face the direction of travel.- Support the lower part of the pistons.- remove the connecting rod bearing screws (1) and remove the two caps

(2).

F3.11

NUDA 900 2012 - NUDA 900 R 2012

H10379

23

64

23

64

H10381

45

45

H10380

1

2

H10382

1 2



Caution: mark the pistons and the relevant cylinders. do not exchange the components: mark the assembly positions.

- remove the split bearings (3) from the two caps (2).

- mark the exhaust side on the pistons.- extract both connecting rods (4) with the pistons (5) downwards, being careful

not to damage the cylinder liners, the crank pins or the split bearings (6).

main bearing cap removal- mark the installation position of the two caps before removing them.- The caps must not be inverted.- remove the screws (1) and the two caps (2).

Crankshaft removal- release the timing chain (1) and remove it, marking the rotation direction.- remove the crankshaft (2).

F3.12

NUDA 900 2012 - NUDA 900 R 2012

H10383

11

1

1

22

3

3

H10384

2

1

H103851

23

4

2

H10386



main split bearing removal- mark the installation positions of the split bearings.- remove the split bearings (1) from the upper crankcase, the split bearings (2)

of the main bearing caps and the split bearings (3) of the lower crankcase.

Chain tensioner slider removal- Take out the screw (1) and remove the chain tensioner slider (2).

Piston removal- Tighten the connecting rod (1) in the vice with the protective jaws.- remove the retaining rings (2).- remove the piston pins (3).- Check the wear of the piston pins and replace them if scored or ruined.- Visually check the wear of the piston (4), in particular if there are traces of

wear and grooves.

- Using a bracket gauge, measure the diameter of the piston at a right angle in the direction of the piston pin.

Piston diameter new, transverse to piston pin axis, above piston lower edge by 10 mm refer to the table with

the wear limits for the correct valuesWear limit, transverse

to piston pin axis, above piston lower edge

- if the measured values are lower than the wear limit, the piston must be replaced.

F3.13

NUDA 900 2012 - NUDA 900 R 2012

H10387

H10388

1

32

4

H10389

1

4



Piston ring removalremove the piston rings and the scraper ring using suitable pliers.- Visually check the grooves of the piston rings.

Piston ring assembly- insert a metal wire (3) through the two eyelets of the undulated torsion spring

(2), leave an equal length of wire on both sides, do not shorten it.- Fit the torsion spring (2) with metal wire (3).- Fit the support ring (4) at the bottom using the pliers for piston rings in the

3rd groove of the piston.- Fit the support ring (1) at the top using the pliers for piston rings in the 1st

groove of the piston.

Form of piston segment 3rd Scraper ring type

Form of piston segment 2nd groove

Tapered type with prong

Piston ring assembly direction "Top" mark pointing up

Form of piston segment 1st groove

rectangular section type

Piston ring assembly direction "Top" mark pointing up

F3.14

NUDA 900 2012 - NUDA 900 R 2012

H10390

21 1

1

H10391

1

2

3

H10392

4



Piston installation- Whenfittingthepistonpin,makesurethattheversionofthepinandthe

connecting rod are the same.- lubricate the piston pins with engine oil.- Heat the piston to approx. 50°C.- insert the connecting rod and the piston pins (2), paying attention to the

installation position.- The mark on the connecting rod small end (arrow) must indicate the exhaust

side (pay attention to the mark on the piston crown).

Caution: loose piston rings or piston pins can damage the cylinder liner. make sure that the piston rings are perfectly positioned on the piston

pin!

- Fit the new safety rings (1).- Hook the safety ring with the prong in the notch and press them in the groove,

theringmustengagecorrectlyinthespecificseat.

installing the pistons with the connecting rod- Turn the engine to the installation position.- Pay attention that the gaps between the sealing rings do not coincide with

the piston rotation axis.- Turn both the piston ring gaps (3) approx. 30° with respect to each other

(lens).- Offset the gaps of the other piston rings (2), (1) respectively 120° with respect

to the upper gap of the scraper ring .

- lubricate the sliding surface of the cylinder and the piston jacket with engine oil.

- insert the connecting rod and the piston in the cylinder, paying attention to the installation direction (arrow (4) on the piston crown must face towards the exhaust); and to not ruining the cylinder surface with the piston rings.

F3.15

NUDA 900 2012 - NUDA 900 R 2012

H10393

1

2

H10394

H10395

1 2



Chain tensioning slider installation- Clean the threading.- insert the chain tensioner slider (2) and tighten the screw (1) to the required

torque.

main split bearing installation- Turn the upper crankcase of the engine and support the pistons inside the

cylinders.- Check the split bearings for wear or breakage and replace them if neces-

sary.- Clean the split bearings and the relevant seats.

Caution: The lubrication holes of the split bearings must be located above

the oil channels.

- Fit all the split bearings in pairs, inserting the prongs in the respective seats.

Warning: if the crankshaft is replaced, also replace the main split bearings.

Crankshaft installation- Clean the sealing surfaces.- Beforefittingthecrankshaft(2)lubricateallsupportingpointswithengine

oil.- insert the crankshaft (2), positioning the timing chain (1) on the crankshaft

gear.- Pay attention to the direction of rotation of the timing chain.- Check the correct housing of the cylinder connecting rods on the crank-

shaft.

F3.16

NUDA 900 2012 - NUDA 900 R 2012

H10396

13

2

3

3 3

H10397

85

67

41

23

H10398

1

2

H10399



main bearing cap installation- Clean and lubricate all support surfaces.- Fit the caps (2), making sure the reference pins (3) are correctly posi-

tioned.- Pay attention to the installation position marks.

- Tighten the screws (1) to torque according to the indicated sequence (from 1 to8),thenperformthefinaltighteningasspecifiedintherelevantchapter.

Caution: The screws must be replaced at each reassembly.

Connecting rod cap installation- Clean and lubricate the contact surfaces of the connecting rod and the con-

necting rod caps.- lubricate the sliding surfaces with engine oil.- Fit the caps (2) on the connecting rods, paying attention to the marks (ar-

rows).- replace the screws (1) and tighten them to torque on the connecting rod caps,

alternatingthem,thenperformfinaltighteningasspecifiedintherelevantchapter.


F3.17

NUDA 900 2012 - NUDA 900 R 2012

H10400

H104011

3

2

H10402

H10403



Compensation arm installation- insert the split bearings with the prong (arrow) in the connecting rod caps

and in the compensation arm.

- Clean and lubricate all the connecting rod separation surfaces.- Lubricatetheslidingsurfaceswithengineoil,fittheconnectingrodcaps(2)

and the balancing connecting rod (3), paying attention to the mark (arrow).- The marks face forward in the direction of travel.- replace the screws (1).

- Orient the compensation arm.


- Tightenthescrews(1)asspecifiedintherelevantchapter.

F3.18

NUDA 900 2012 - NUDA 900 R 2012

H10404

2

1

H10405

2

1

H10407

4

11

23

5

H10433

1

2

3



Gear selector drum installation- Clean the threading.- Clean the control roller and the supporting points and lubricate them with

engine oil.- Fit the selector drum with the bearing (2) in the section of the crankcase.- Tighten the screw (1) to torque (loctite 243).

installation of the 5th/6th gear engagement fork- Check the wear of the fork (2) and the pin (1); if worn or ruined, replace

them.- Clean all components and lubricate them with engine oil.- Turn the selector drum to the neutral position.- Fit the engagement fork (2) on the selector drum.- Fully insert the pin (1) from the crankcase side and in the fork (2).- Check that the fork was correctly inserted in the drum and that it moves

freely.

installation of the 1st/3rd and 2nd/4th gear engagement fork- Check the wear of the forks (3) and the pin (2), replace them if worn or ru-

ined.- Clean all components and lubricate them with engine oil.- Fit the engagement forks (3) on the selector drum.- Fully insert the pin (2).- Check that the forks (3) were correctly inserted in the drum and that they

move freely.- lubricate the stop pin (1) and install it.

Ratchet installation- lubricate the components with engine oil.- Fitthebushing(2)onthelever(3),thenfitontothespring(1),engagingthe

hook (5) on the lever and the spring (1) in its seat in the engine crankcase.- Tighten the screw (4) to torque.

F3.19

NUDA 900 2012 - NUDA 900 R 2012

H10408

2

4

3

1

H104091

2

H10410



star-shaped stop element installation- move the ratchet to the side (1) with a screwdriver and insert the start-shaped

stop element (3); correctly insert the pin (4) in the hole (5) of the drum.- Tighten the screw (2) to torque.

Reassembly of the gearbox input and output shaft - Clean all the supporting points and lubricate them with engine oil.- Fit the shafts (1) and (2).

- Turnthebearingofthegearboxoutputshaftandtherelevantfixingringstothe installation position.

- The pin (arrow) must be in the notch of the engine crankcase half.- Position the notch of the bearing stop ring upwards (arrow), it must not be

positioned between the sealing surfaces.

F3.20

NUDA 900 2012 - NUDA 900 R 2012

H10411

2 3

1

H10412

2

1

H10413

H10450



installation of the lower part of the engine crankcase half

apply a layer of sealant on the lower part of the crankcase.

Caution: accidentally plugging the throttle valve or the oil channel damages

the gearbox, because the main oil supply is interrupted. Carefully apply sealant.

- Clean the sealing surfaces.- apply a layer of loctite 5910 sealant (or dow Corning) in the zone represented

on the lower part of the crankcase.- apply a layer of sealant in the sector (1) on the external edge, because in

this sector the throttle (2) and the oil pipe (3) are located in the upper part of the engine crankcase half.

- Beforefittingthelowerpartoftheenginecrankcasehalf,makesurethatthestar coupling (1) is in the neutral position (arrow).

- Thesafetypin(2)mustbefit.

- Positionthegearsasshowninthefigure.- move the gearbox to the neutral position, it must be possible to turn the gears

individually.

F3.21

NUDA 900 2012 - NUDA 900 R 2012

H10414

1

H10415

H10416

H10417

1



- Check that the crankshaft split bearings (1) are inserted correctly in their seats.

- lubricate the split bearings with engine oil.

- When inserting the lower part of the engine crankcase half, pay attention to the centring pins.

- Check the correct position of the gearbox bearing:- The pin (arrow) must be in the notch of the engine crankcase half.- Positionthenotch(arrow)ofthebearingfixingringupward.

- Orient the compensation arm upwards and place the lower part of the engine crankcase half (1) on the upper one.

- manually tighten the screws down fully, paying attention to their length.

F3.22

NUDA 900 2012 - NUDA 900 R 2012

H10419

H10420

1 4 9

23

5

67

8

H10422

10

11

H10434

2

1

3



Fixing the compensation arm- Orient the compensation arm (3) downwards.- Press the bearing pin down fully.- Use a suitable tool to insert the pin (2) in the compensation arm.- Fit the safety pin (1).

- Orient the engine in the installation position and fully screw down the screws manually, paying attention to their length.

Fixing the crankcase halves- rotate the engine upwards with the lower part of the relevant crankcase.- Tighten the screws (from 1 to 4) according to the indicated sequence, and

accordingtowhatisspecifiedintherelevantchapter.- Tighten the screws to torque in the installation sequence from (5) to (9).

Caution: The screws (1) to (4) must be replaced after each removal.

- rotate the engine with the part of the crankcase in the installation position.- Tighten the screws to torque in the installation sequence from 10 to 11.

F3.23

NUDA 900 2012 - NUDA 900 R 2012

H10423

16

15

23

201413

1912

21

2217

18

H104261



- Tighten the screws to torque in the installation sequence from 12 to 23.

Gearbox output shaft oil seal installation- Fill the new oil seal between the inner sealing lips with grease.- Clean the crankcase.- Fittheoilseal(1)ontheouterside,usingaspecificpad,beingcarefulto

protect the inner lip from the scoring on the shaft.

Refitallthepreviouslyremovedcomponentsasdescribedintherelevantpara-graphs.

F4.1

NUDA 900 2012 - NUDA 900 R 2012

F4


ENGINE TORQUE FIGURES

Section

Tighten all nuts and screws to the specified torque using a torque wrench. An insufficiently tightened screw or nut could get damaged or come completely loose, damaging the motorcycle and/or injuring the rider. A screw or nut tightened beyond the permitted max. torque value might get damaged or break and therefore come completely loose. The specified values refer to clean threads.

F4.2

NUDA 900 2012 - NUDA 900 R 2012



KEY

A : Lubricate with engine oil.B : Grease.C : Tighten manually.

CONVERSION TABLE1 Nm = 0.1 Kgm1 Nm = 0.73756 ft/lb

F4.3

NUDA 900 2012 - NUDA 900 R 2012

H10454

12 Nm 30 Nm

12 Nm

Loctite 648

Loctite 5910

Loctite 648

25 Nm

12 Nm1) 15 Nm2) 80° ± 5°

12 Nm

1) 15 Nm2) 45° ± 5°

19 Nm

19 Nm

12 Nm

10 Nm

Klueber 46 MR

AA

A

* *



* = Replace the screws at each reassembly!

F4.4

NUDA 900 2012 - NUDA 900 R 2012

H10455

12 NmLoctite 243

40 Nm

12 NmLoctite 243

14 Nm

12 Nm12 Nm

10 Nm

30 Nm

A

12 Nm

1) 5 Nm2) 20 Nm*



paolo

Rettangolo

F4.5

NUDA 900 2012 - NUDA 900 R 2012

H10456

1) 10 Nm2) 30 Nm3) 135°

1) 5 Nm2) 20 Nm3) 95°

AA

A

A

1) 5 Nm, 2) 20 Nm3) 95°

*

**



* = Replace the screws at each reassembly!

F4.6

NUDA 900 2012 - NUDA 900 R 2012

H10457

10 Nm

17 mm ± 1 mm

30,5 mm ± 1 mm

20 Nm

19 Nm

10 Nm

1) 30 Nm2) 270° *



* = Replace the screws and the head gasket at each reassembly!

F4.7

NUDA 900 2012 - NUDA 900 R 2012

H10458

10 NmLoctite 243

40 Nm

10 Nm

50 Nm Loctite 243



F4.8

NUDA 900 2012 - NUDA 900 R 2012

H10459

Three Bond 1209

10 Nm

10 Nm Loctite 243



F4.9

NUDA 900 2012 - NUDA 900 R 2012

H10460

30 Nm

12 Nm

12 Nm

10 NmThree Bond 1209

Klueber 46 MR 401

Loctite 243

C 5 Nm

A

A

**

H10461

50 Nm Loctite 243

Klueber 46 MR 401



** = Left-hand thread

F4.10

NUDA 900 2012 - NUDA 900 R 2012

H10462

B

5 Nm Loctite 243

10 Nm Loctite 243 10 Nm

10 Nm Loctite 243



F4.11

NUDA 900 2012 - NUDA 900 R 2012

H10463

180 Nm Loctite 648

10 Nm

Klueber 46 MR 401



F4.12

NUDA 900 2012 - NUDA 900 R 2012

H1046412 Nm

C



F4.13

NUDA 900 2012 - NUDA 900 R 2012

H1046510 Nm

B

Three Bond 1209

4 Nm Loctite 243

10 Nm

11 Nm ± 12%

Klueber 46 MR 401

Klueber 46 MR 401

Loctite 648

35 NmLoctite 648

140 NmLoctite 648

10 NmLoctite 423



F4.14

NUDA 900 2012 - NUDA 900 R 2012

H10466

12 Nm



F5.1

NUDA 900 2012 - NUDA 900 R 2012

F5

WeAR limits of eNgiNe pARts

Workshop manual ed. 11-2011

Section

F5.2

NUDA 900 2012 - NUDA 900 R 2012



EnginE wEar valuE tablE .................................................................F5.3Crankshaft / Casing assy. .........................................................................F5.3Connecting rod ...........................................................................................F5.3Compensation connecting rod compensation arm .....................................F5.3gearbox ......................................................................................................F5.4gear shift control ........................................................................................F5.5Clutch .........................................................................................................F5.6Piston..........................................................................................................F5.6Piston pin ....................................................................................................F5.7Cylinders / Casing assy. .............................................................................F5.7timing chain ...............................................................................................F5.7Head ...........................................................................................................F5.7valves .........................................................................................................F5.8Oil pump .....................................................................................................F5.9Starting device ............................................................................................F5.9Spark plug ..................................................................................................F5.9

F5.3

NUDA 900 2012 - NUDA 900 R 2012



EnginE wEar valuE tablEDescription Part Measurement

pointnew value [mm] wear limit [mm] remarks

Crankshaft / Casing assy. radial clearance / Crankshaft - Main bear-ing

Crankshaft / Casing assy. / 50x54x14 bushing

4 bearing points, in direc-tion of travel 0.03 - 0.06 mm max. 0.08 mm

Crankshaft - Ø main bear-ing points Crankshaft assy. 4 bearing points Ø 50 -0.004/-0.02 mm min. Ø 49.97 mm

Casing - Ø main bearing points

Casing assy. / 50x54x14 bushing

4 bearing points, in direc-tion of travel Ø 50.02 - 50.06 mm max. Ø 50.08 mm

Perform a visual check

Crankshaft - axial clear-ance

Crankshaft / Casing assy.

- Crankshaft thrust ring measurement:

20.0 0/+0.05 mm- Casing thrust ring meas-

urement: 19.8 +/- 0.05 mmaxial clearance: 0.15 - 0.30 mm

max. 0.45 mm

Crankshaft unbalance Crankshaft assy.

Crankshaft support on both external main bear-ings.Measurement points: in both main inner bearing points

0.03 mm max. 0.04 mm

Connecting rodCrankshaft - Ø connect-ing rod pin Crankshaft assy. Ø 45 -0.016/-0.032 mm

(Ø 44.968 - 44.984 mm) min. Ø 44.95 mm

Connecting rod stem - Ø big end

Connecting rod stem assy. / 45x48x15 bush-ing

Measurement in the di-rection of travel Ø 45.01 - 45.03 mm

max. Ø 45.05 mmSmall traces of cavitation are permitted

big end radial clearanceCrankshaft assy. / Con-necting rod stem assy. / 45x48x15 bushing

in the direction of travel 0.026 - 0.062 mm max. 0.08 mm

Connecting rod stem - Ø small end

Connecting rod stem assy. in the direction of travel Ø 18 +0.02/+0.01 mm max. Ø 18.04 mm

radial clearancesmall connecting rod end

Connecting rod stem assy. / Piston pin in the direction of travel 0.008 - 0.025 mm max. 0.04 mm

Connecting rod stem assy. axial clearance

Connecting rod stem assy. / Crankshaft assy.

Connecting rod stem: 19 0/-0.052 mmCrankshaft: 19.2 +/-0.1 mmaxial clearance: 0.1 - 0.352 mm

max. 0.4 mm

Compensation connecting rod compensation arm

Compensation connect-ing rod - Ø big end

Compensation connect-ing rod assy. / 55x59x18 bushing

in the direction of travel Ø 55.01 - 55.03 mm max. Ø 55.04 mm

Crankshaft - Ø bearing points for compensation connecting rod

Crankshaft assy. Ø 55 -0.034/-0.05 min. Ø 54.94 mm

radial clearanceCrankshaft - compensa-tion connecting rod

Crankshaft assy. / Com-pensation connecting rod assy. / 55x59x18 bushing

0.044 - 0.08 mm max. 0.09 mm

Compensation connect-ing rod - Ø small end

Compensation connect-ing rod assy. Ø 28 +0.015/+0.007

max. Ø 28.025 mmno sign of pitting is per-mitted.

F5.4

NUDA 900 2012 - NUDA 900 R 2012





Ø compensation pin Compensation pin Ø 22 0/-0.003

min. Ø 21.98 mmno signs of pitting are permitted on the compen-sation pin or on the nee-dle roller bearing rollers.

Compensation connect-ing rod - small end radial clearance

Compensation connect-ing rod assy. / Compen-sation pin / 22x28x22 needle roller bearings

0.011 - 0.028 mm

max. 0.04 mmno relevant radial clear-ance. Swing the com-pensation connecting rod - irregular travel is not permitted.

Ø bearing pin bearing pin Ø 16 +0.007/+0.014 mm min. Ø 16.00 mm

Compensation arm - Ø bearing bore Compensation arm Ø 16 +0.019/+0.029 mm max. Ø 16.05 mm

Compensation arm radial clearancebearing pin

Compensation arm / bearing pin 0.005 - 0.022 mm max. 0.04 mm

Casing - Ø bore for bear-ing pin Casing assy. Measured horizontally

(direction of travel) Ø 16 +0.016/+0.034 mm max. Ø 16.06 mm

gearbox

bore in the casing for deep-groove ball bear-ings of the gear shafts

Casing assy.

Magnet side main shaft. Clutch side main shaft.Magnet s ide ou tput shaft.Clutch side output shaft.

Ø 72 -0.045/-0.065 mmØ 52 -0.045/-0.065 mmØ 47 -0.045/-0.065 mm

Ø 62 -0.055/-0.065 mm

Perform a visual check

Main shaft - Ø bearing points Main shaft

Main bearing support, magnet side.Main bearing support, clutch side.bearing point, neutral gear 1st/2nd and 3rd/4th

gear

Ø 30 +0.002/+0.011 mm

Ø 20 0 -0.013 mm

Ø 25 0 -0.013 mm

min. Ø 29.99 mm

min. Ø 19.97 mm

min. Ø 24.97 mm

Output shaft - Ø bearing points Output shaft Z13

Main bearing support, magnet side.Main bearing support, clutch side.bearing point, neutral gear 5th gearbearing point, neutral gear 6th gear

Ø 25 0 -0.013 mm

Ø 30 +0.008/+0.017 mm

Ø 29 +0.041/+0.054 mm

Ø 25 0 -0.013 mm

min. Ø 24.97 mm

min. Ø 29.99 mm

min. Ø 29.03 mm

min. Ø 24.97 mm

Permitted deformation Main shaft/ output shaft Z13

inserted in the main bear-ing points (not between points).

0.01 mm max. 0.02 mm

F5.5

NUDA 900 2012 - NUDA 900 R 2012





gearbox - visual check gearbox assy. / all gears / main shaft / output shaft

visual check of the teeth sides (small grey marks and individual pits up to approx. 0.5% of the side surface are permitted).

visual check of the en-gagements and relative openings.

Check the operation and adjust all the wheels on the main shaft and on the output shaft after in-stallation.

Check that the gear shafts rotate easily after installation.

5th gear neutral gear- Ø bearing points

neutral gear Z24 - version with sliding bearings Ø 29 +0.08/+0.10 mm max. Ø 29.15 mm

gearbox gears - groove width for control fork

gearbox gear Z24 / gear-box gear Z25 / gearbox gear Z21/23

6.1 0/+0.1 mm max. 6.25 mm

gear shift control

thickness of the gear en-gagement fork plates

Engagement fork 1st/3rd gearEngagement fork 2nd/4th gearEngagement fork 5th/6th gear

5.9 0/-0.075 mm min. 5.60 mm

axial clearance of the engagement forks in the corresponding grooves of the gearbox gears

gearbox gear Z24 / gear-box gear Z25 / gearbox gear Z21/23

0.2 - 0.375 mm max. 0.60 mmEngagement fork 1st/3rd gearEngagement fork 2nd/4th gearEngagement fork 5th/6th gear

width of the groove in the selector drum Selector drum 9.1 0/+0.06 mm max. 9.40 mm

Deformation of the fork shaft 2 selector shafts max. 0.02 mm max. 0.02 mm

Deformation of the gear-box shaft gearbox shaft assy. max. 0.1 mm max. 0.1 mm

F5.6

NUDA 900 2012 - NUDA 900 R 2012





ClutchClutch plates - permitted deformation

9 1.5 mm steel plates9 3.5 mm lined plates max. 0.15 mm max. 0.15 mm

Clutch plate pack assy. height

9 1.5 mm steel plates9 3.5 mm lined plates

1.5 +/-0.05 mm3.5 +/-0.08 43.83 - 46.17 mm min. 43.8 mm

lined clutch plates - thickness 9 3.5 mm lined plates

gasket thickness.lined plate pack height (9 pcs)

3.5 +/-0.08 mm30.78 - 32.22 mm

min. 3.4 mmmin. 30.60 mm

Clutch spring - relieving length

6 spr ings for c lutch DM18.5 D2.25 l65.05

l0 = 65.05 mm210 +/- 7 n a l1=26mm min. 62.0 mm

lined plates - Driver width 9 3.5 mm lined plates

7 pcs: 14 -0.05/-0.015 mm2 pcs (upper and lower friction plate):13 0/-0.03 mm

7 pcs: min. 13.7 mm

2 pcs (upper and lower friction plate):min. 12.9 mm

gear Z68 clutch housing - bearing bore Clutch housing assy. 35 +0.010/-0.002 mm max. Ø 35.03 mm

notch depth: check the presence of notches in the guide grooves of the clutch housing and in the outer toothing of the driver.

Clutch housing assy. / Driver 0 mm max. 0.3 mm

Piston

Ø piston Piston assy. 83.97 mm (with graphite layer)

Measured 4 mm from the lower edge of the piston, transversally to the piston pin axis

Ø 83.966 +/-0.012 mm min. Ø 83.94

Piston installation clear-ance

Piston assy. 83.97 mm / Casing assy. 0.015 - 0.053 mm max. 0.10 mm

Ø piston pin end Piston assy. 83.97 mm Measured in the direction of travel. Ø 18 +0.010/+0.015 max. Ø 18.03 mm

1st ring 1st ring r 84/77.8/1.2 / Piston assy. 83.97 mm

gap at the end (of the ring).ring height.Height of the slot (on the piston).axial clearance.

0.2 - 0.35 mm

1.2 -0.01/-0.031.2 +0.02/+0.04

0.03 - 0.07

max. 1.0 mm

min. 1.15 mmmax. 1.30 mm

max. 0.12 mm

2nd ring 2nd ring 84/76.8/1.2 / Piston assy. 83.97 mm

gap at the end (of the ring).ring height.Height of the slot (on the piston).axial clearance.

0.35 - 0.55 mm

1.2 -0.01/-0.031.2 +0.01/+0.03

0.02 - 0.06

max. 1.2 mm

min. 1.15 mmmax. 1.30 mm

max. 0.12 mm

3rd ring (scraper ring)3rd ring S niFFlEX 84/79.1/2.0 / Piston assy. 83.97 mm

gap at the end (of the ring). ring height.

0.2 - 0.7 mm2.0 +0.01/+0.03

max. 1.0 mmmax. 2.10 mm

ring height and axial clearance not measur-able.

F5.7

NUDA 900 2012 - NUDA 900 R 2012





Piston pin

Ø piston pin PiStOn Pin 18/11x50 Ø 18 +0.002/-0.005 mm

min. Ø 17.98 mmDetachments in the DlC coating are not permit-ted.

Connecting rod small end radial clearance

Connecting rod stem assy. / PiStOn Pin 18/11x50

Measured in the direction of travel. 0.008 - 0.025 mm max. 0.04 mm

Piston / piston pin radial clearance PiStOn Pin 18/11x50 Measured in the direction

of travel. 0.008 - 0.025 max. 0.04 mm

Cylinders / Casing assy.

Ø cylinder bore Casing assy.

Ø cylinder measured 31 - 36 mm from the upper edge, in 2 points (in the direction of travel and transversely to the direc-tion of travel).

Ø 84 +/-0.007 max. Ø 84.03 mm

Compression pressureMeasurement with valve clearance correctly ad-justed.

17 bar 13 bar

Permitted deformation of the sealing surface Casing assy. On the entire surface. max. 0.05 mm max. 0.05 mm

timing chainlengthening of the tim-ing chain

t i M i n g C H a i n 6.35X10.9X146 - - Measurable only with a

special tool.

Depth of the traces of wear in the chain ten-sioner slider and in the chain guide

Chain tensioner pad / Chain guide / upper chain guide

0 mm max. 0.8 mm

HeadDiameter of chain ten-sioner holes Cylinder head assy. Ø 14 +0.006/+0.024 max. Ø 14.05 mm

Permitted deformation of the sealing surface Cylinder head assy. On the entire surface. max. 0.03 mm max. 0.04 mm

intake cam height intake camshaft 39.97 +/-0.1 mm min. 39.85 mm

Exhaust cam height Exhaust camshaft 39.97 +/-0.1 mm min. 39.85 mm

bearing bore for both camshafts Cylinder head assy. 6 bearing points Ø 25 +0.02/+0.041 max. Ø 25.06 mm

Camshafts - bearing points

intake camshaft / Exhaust camshaft every 3 bearing points Ø 25 0 -0.013 mm min. Ø 24.97 mm

Camshaft radial clear-ance in cylinder head

Cylinder head assy. / in-take - Exhaust camshaft 6 bearing points 0.02 - 0.054 mm max. 0.08 mm

axial thrust surface of camshafts

intake camshaft / Exhaust camshaft Cam gear side 21 0/+0.05 mm max. 21.08 mm

axial thrust surface of camshaft bearing cap

Camshaft bearing cap / Cylinder head assy.

Camshaft bearing cap - Cam gear side 20.93 0/-0.05 mm min. 20.75 mm

Camshaft axial clear-ance

Cylinder head assy. / in-take - exhaust camshaft 0.07 - 0.17 mm max. 0.3 mm

rocker arm - shaft seat rocker arm Ø 12 +0.016/+0.034 max. Ø 12.05 mm

rocker arm - shaft seat rocker arm shaft Ø 12 -0.016/-0.027 min. Ø 11.96 mm

valve spring - Spring relieving length (lo) valve spring 48.8 mm min. 47.5 mm

F5.8

NUDA 900 2012 - NUDA 900 R 2012





valves

intake valve clearance intake valve 33 mm with cold engine (max. 35°C) 0.23 - 0.33 mm 0.23 - 0.33 mm

Exhaust valve clearance Exhaust valve 28.5mm with cold engine (max. 35°C) 0.30 - 0.41 mm 0.30 - 0.41 mm

valve stem - Permitted unbalance

intake valve 31/33mm / Exhaust valve 27.5/28.5 mm

On stem / on spring re-tainer



valve seat wearintake valve 31/33mm / Exhaust valve 27.5/28.5 mm

Check with a ruler, the support surface must not be concave

- -

intake valve - Ø valve stem intake valve 31/33 mm Ø 4.973 +/- 0.007 mm min. Ø 4.950mm

Exhaust valve - Ø valve stem

E x h a u s t v a l v e 27.5/28.5mm Ø 4.963 +/- 0.007 mm min. Ø 4.940mm

valve guide - wear limit Ø bore Cylinder head assy. Measured with gauge Ø 5 H7 (0/+0.012) max. Ø 5.04 mm

intake valve - valve stem radial clearance

Cylinder head assy. / in-take valve 31/33mm 0.02 - 0.046 mm max. 0.07 mm

Exhaust valve - valve stem radial clearance

Cyl inder head assy. / E x h a u s t v a l v e 27.5/28.5mm

0.03 - 0.056 mm max. 0.08 mm

width of the inserted, intake valve seat Cylinder head assy. 1.2 +/-0.15 mm max. 1.8 mm

width of the inserted, exhaust valve seat Cylinder head assy. 1.4 +/-0.15 mm max. 2.2 mm

F5.9

NUDA 900 2012 - NUDA 900 R 2012





Oil pumpSliding clearance be-tween the inner and the outer rotors

Delivery pump / intake pump max. 0.15 mm max. 0.25 mm

radial clearance between the outer rotor and the casing

Casing assy. / Outer ro-tor 0.08 - 0.20 mm max. 0.25 mm

axial clearance between oil delivery pump and casing

Casing assy. / Delivery pump / Cover 0.02 - 0.09 mm max. 0.15 mm

grooves are permitted on the cover and in the casing

axial clearance between oil intake pump and cas-ing

Casing assy. / intake pump / Cover 0.02 - 0.14 mm max. 0.18 mm

grooves are permitted on the cover and in the casing

Oil pressure

insert the oil pressure gauge in the head in the place of the M12x1.5 screw plug.Measurement at an oil temperature of 80°C.

1.5 bar at 1250 rpm (neu-tral)

5.2 bar at 5000 rpm

1.0 bar at 1250 rpm

3.5 bar at 5000 rpm

Starting deviceSeat of the freewheel control gear Z64 on the crankshaft

Crankshaft assy. Ø 31.75 0/-0.013 mm min. Ø 31.72 mm

Spark plug

Electrode gap Spark plug 10, ngK lMar8C-9 0.9 0/-0.1 max. 1.2 mm

I.1

NUDA 900 2012 - NUDA 900 R 2012

I


FRONT SUSPENSION

Section

I.2

NUDA 900 2012 - NUDA 900 R 2012

FRONT SUSPENSION


Front end ...................................................................................................... I.3Disassembly ................................................................................................. I.4Assembly ...................................................................................................... I.6Suspension settings summary tables ........................................................... I.8Servicing forks ............................................................................................ I.10Bushing and seal replacement ................................................................... I.13Reassembly ................................................................................................ I.14Servicing damper........................................................................................ I.15Reassembly damper................................................................................... I.17

I.3

NUDA 900 2012 - NUDA 900 R 2012

H10576

12

2

2

3

4

5

6

6

7

7

8


FRONT SUSPENSION

Front end

Key1) Steering nut.2) Fork leg retaining screws.3) Steering head.4) Ring nut.5) Bottom yoke.6) Bearings.7) Dust seal.8) Washer.

I.4

NUDA 900 2012 - NUDA 900 R 2012

H10577

1

1

H10578

2

H10579

3

3H10580

4

FRONT SUSPENSION


DisassemblyRemove the wheel, the headlight, the front mudguard as described in the rel-evant paragraphs.

- Loosen the four screws (1) and move the handlebar without removing it.

Protect carefully the fairings and the painted parts to prevent scratches and/or damages.

- Loosen the nut (2) of the steering tube.

- Loosen the screws (3) from both sides and remove the fork leg stems (4).

I.5

NUDA 900 2012 - NUDA 900 R 2012

H10583

9

8

7

H10584

H10582

6

H10581

2

5

H10585

10


FRONT SUSPENSION

- Fully loosen the nut (2) and remove the steering head (5).

- Loosen the ring nut (6) and remove the bottom yoke (7) with the related bearings (8) and the dust seal (9).

- In case of replacement of the bearings, remove the seats (10) by hitting alternatively on the seat with an aluminium punch.

I.6

NUDA 900 2012 - NUDA 900 R 2012

H10627

3

2

1

H10628

4

H10629

6

5

FRONT SUSPENSION


AssemblyFor the reassembly of the front end, proceed as follows:- Lubricate the bearings with grease before reassembling them.- Install the bottom yoke (1), the upper bearing (2) and the dust seal (3), the

tighten the ring nut (4) to the pre-tightening torque so that the bearings settle on the respective seats (pre-tightening torque is around half the value of the tightening torque).

- Loosen the ring nut (4) and tighten it to the specified tightening torque.

- Install the steering head (5) and tighten manually the nut (6).

I.7

NUDA 900 2012 - NUDA 900 R 2012

H10659

8

7


FRONT SUSPENSION

- Insert the fork stems (7) and position them depending on the type of use as described in the following table; lock them in position by tightening the lower screws (8) to torque.

For the Nuda 900R version, it is possible to adjust the suspension according to the type of use of the motorcycle and its load. It is also possible to adjust the motorcycle suspension for use on the track (Motard version).

I.8

NUDA 900 2012 - NUDA 900 R 2012

H10632

A

“A” =

385 m

m (N

UDA

900 R

Mota

rd)

“A” =

380

mm

(NUD

A 90

0)

“A” =

380

mm

(NUD

A 90

0 R)

H10633

1

21

1

1

1

6

FRONT SUSPENSION


The different adjustments in the table must be performed both on the front fork and on the rear shock absorber.

Suspension settings summary tables

SHOCK ABSORBER NUDA 900 NUDA 900with panniers and pas-senger



Length of shock absorber "A"

- - 380 mm(14.96 in)

385 mm(15.15 in)

380 mm(14.96 in)

Compression adjustment SHOCK ABSORBER


Rebound adjustment shock absorber


Constant "K" spring shock absorber


FORK NUDA 900 NUDA 900with panniers and pas-senger



Compression adjustment - - 6 clicks 3 clicks 6 clicksRebound adjustment - - 10 clicks 10 clicks 10 clicksFork spring constant "K" 6.5 N/mm

7.0 N/mm(dist)

6.5 N/mm7.0 N/mm(dist)

7.0 N/mm7.0 N/mm

7.0 N/mm7.0 N/mm

7.0 N/mm7.0 N/mm

Position of fork "A" 220 mm(8.66 in)

220 mm(8.66 in)

230 mm(9.05 in)

240 mm(9.45 in)

230 mm(9.05 in)

NOTE: Fork springs and shock absorbers with varying degrees of stiffness are available above all for use with passenger and/or panniers.

NOTE: Do not go beyond 385 mm.

I.9

NUDA 900 2012 - NUDA 900 R 2012

H10631

6

H10660

9


FRONT SUSPENSION

- Tighten the nut (6) to torque.

- Tighten the upper screws (9) of the fork leg stems to torque.

Reassemble in reverse order the other components that were previously re-moved.

I.10

NUDA 900 2012 - NUDA 900 R 2012

H10586

H10587

1

2

H10588

3

H10589

4

5

7

FRONT SUSPENSION


Servicing forksNOTE: only for NUDA 900 R: Before starting the fork servicing procedures, make note of its set-

ting (compression, rebound, pre-load), then position the adjuster screws on the maximum opening.

- Loosen the cap (1) from the fork sleeve (2).

- Lower the fork sleeve (2) to gain access to the damper (3).

- Slightly squeeze the spring (4) and insert the key in the nut (5) on the damper rod (7).

I.11

NUDA 900 2012 - NUDA 900 R 2012

H10590

1

H10591

4

H10592

6

H10593

2 7


FRONT SUSPENSION

- Loosen the cap (1) from the rod.

- Remove the spring (4).

- Remove the adjuster rod (6) inside the damper rod (7).

- Turn the fork sleeve (2) upside down so the oil can come out.- Move the rod (7) so the oil can come out easily.

I.12

NUDA 900 2012 - NUDA 900 R 2012

H105948

H10595

H10596

H10597

9

FRONT SUSPENSION


- Lock the foot (8) with a vice with aluminium jaws.

- Insert the proper tool in the fork leg to lock the bushing of the damper.

- Fit the tool in the respective seats of the damper so that it does not turn while you loosen the valve assembly.

- Loosen the bottom valve assembly (9). NOTE: Be careful if the oil comes out.

I.13

NUDA 900 2012 - NUDA 900 R 2012

H10598

9

H10599

10

H10600

11

H10601

12


FRONT SUSPENSION

- Remove the bottom valve assembly (9).

- Remove the damper (10) from the fork sleeve.

Bushings and seals replacement- Use a screwdriver to remove the dust seal (11) making sure not to damage

it.

- Use a flat head screwdriver to remove the retaining ring (12).

I.14

NUDA 900 2012 - NUDA 900 R 2012

H10602

2

13

H10603

H10604

11

H10605

14

FRONT SUSPENSION


- Open with light hits the fork leg (13) from the fork sleeve (2) until they sepa-rate.

- Remove the bushings and the sealing rings from the fork leg.- Check the bushings for wear and tear. If they show wear replace them.

Assembly- Insert again the dust seal (11) with a suitable tool to prevent the cutting of

the sealing ring lip.

Ensure the correct direction of assembly.

- Insert again the sealing ring (14) with a suitable tool to prevent the cutting of the lip.

Ensure the correct direction of assembly.

I.15

NUDA 900 2012 - NUDA 900 R 2012

H10606

2

13

H10607

H10608

12

H10609

10


FRONT SUSPENSION

- Insert again the fork leg (13) in the fork sleeve (2).

- With a suitable tool, press on the sealing ring (14) until it is fully inserted in the seat.

- Make sure that you do not deform it and ensure that it is fully inserted.

- Reassemble the ring (12) that retains the sealing ring (14) in the seat ensur-ing that it is correctly positioned in the seat, then install the dust seal (11).

Servicing of the damper- Tighten the damper (10) with a vice by using two shaped shells and ensure

that the damper is not deformed.

I.16

NUDA 900 2012 - NUDA 900 R 2012

H10610

15

H10611

15

H10612

15

H10613

16

FRONT SUSPENSION


- Heat the area of the bushing (15) in order to remove the Loctite.

- Loosen the bushing (15) with a suitable tool.

- Remove the bushing (15) with the damper rod.

- Check the piston / reeds assembly (16) and, if needed, replace the defective parts.

I.17

NUDA 900 2012 - NUDA 900 R 2012

H10614

7

H10615

15

H10616

10

13

H10617

9


FRONT SUSPENSION

Damper reassembly- Insert again the rod assembly (7) in the damper (10).

- Tighten the bushing (15) with Loctite 243 using a suitable tool.

- Insert again the damper assembly (10) in the fork leg (13).

- Reassemble the bottom valve (9) applying Loctite 242 on the thread.

I.18

NUDA 900 2012 - NUDA 900 R 2012

H10618

H10619

6

H10620

2

H10621

FRONT SUSPENSION


- Tighten the bottom valve to torque (50 Nm, 5 Kgm, 36.88 ft/lb).

- Insert again the adjustment rod (6).

- Pour the oil in the fork sleeve (2): - 598 cc. for NUDA 900; - 585 cc. for NUDA 900 R.

- After filling the cartridge, check the oil level. From the edge of the fork sleeve with leg fully butted up, it must be: - 110 mm (4.33 in.) for NUDA 900; - 125 mm (4.92 in.) for NUDA 900 R.

I.19

NUDA 900 2012 - NUDA 900 R 2012

H10622

H10623

4

H10624

1

H10625

1


FRONT SUSPENSION

- Possibly, use a syringe to correct the level.

- Insert a spring (4) and possibly a pre-load tube.

- Tighten the cap (1) on the rod (20 Nm, 2.0 Kgm, 14.75 ft/lb).

- Tighten the cap (1) on the fork sleeve (20 Nm, 2 Kgm, 14.75 ft/lb).

I.20

NUDA 900 2012 - NUDA 900 R 2012

H10626

FRONT SUSPENSION


NOTE: only for NUDA 900 R: At the end, restore the adjustments that were recorded before the

servicing procedures.

J.1

NUDA 900 2012 - NUDA 900 R 2012

J


REAR SUSPENSION

Section

J.2

NUDA 900 2012 - NUDA 900 R 2012

REAR SUSPENSION


Rear suspension............................................................................................J.3Rear shock absorber replacement ................................................................J.3Spring rear shock absorber replacement ......................................................J.4Mudguard / chain guard removal ...................................................................J.6Sprocket casing removal. ..............................................................................J.7Rear swinging arm removal. ..........................................................................J.8Chain upper slider removal............................................................................J.9Chain lower slider removal ..........................................................................J.10

J.3

NUDA 900 2012 - NUDA 900 R 2012

H106341

H106352

H10636

4

3

H10637

3

H10638

4

35

5


REAR SUSPENSION

Rear suspensionThis motorcycle suspension is direct. The spring pre-load of the shock absorber can be adjusted to suit riding and terrain conditions. With regard to the hydraulic adjustments, refer to the chapter “Settings and Adjustments”.Periodically check all components for wear.

Rear shock absorber removal- Remove the fuel tank as described in the relevant paragraph.- Position a suitable support under the engine and make sure that the motor-

cycle does not move.- Loosen the nut (1) and remove the pin (2).

- Loosen the upper pin (3) and remove it.- Remove the shock absorber (4)- During the reassembly, position the upper bushings (5) correctly.

J.4

NUDA 900 2012 - NUDA 900 R 2012

H10639

3

2 1

H10640

3

4

H10641

3

REAR SUSPENSION


Rear shock absorber spring replacement

Put soft jaws on the vice and lock the shock absorber.- Fully loosen until the end stroke the lock ring nut (1) and the ring nut (2) in

order to discharge the spring (3).

- Compress the spring, remove the spring retainer (4) and remove the spring (3).

J.5

NUDA 900 2012 - NUDA 900 R 2012

H10642

1

2

5

H10643

B

C

NUDA 900

NUDA 900 R


REAR SUSPENSION

- Check the ring nuts (1) and (2) and the washer (5) for wear: if they show wear or they are damaged, replace them.

- Install the new spring, tighten the ring nut (2) and restore the correct length (pre-load) as the drawing “A” shows.

Drawing "A"

B= spring in seat 162.5 ±15 mm (6.4 ± 0.59 in.)C= spring in seat 181 mm (7.13 in.)

J.6

NUDA 900 2012 - NUDA 900 R 2012

H10644

2 1

H10645

2

H10926

1

REAR SUSPENSION


- Tighten the lock ring nut (1) to torque.

Mudguard / chain guard removal- Loosen the screws (1) and remove the mudguard / chain guard (2) slipping

it off towards the rear side.

J.7

NUDA 900 2012 - NUDA 900 R 2012

H10646

14

3

H10647

1

1

2

3

H106483


REAR SUSPENSION

- During the reassembly, make sure that the bushings are correctly positioned and that the rear brake hose (3) and the speed sensor wire (4) are correctly inserted in their respective seats.

Sprocket casing removal- Loosen the two screws (1) and the screw (2), then remove the cover (3).

NOTE: During reassembly, do not invert the screws, but install them again exactly in the original position.

J.8

NUDA 900 2012 - NUDA 900 R 2012

H106352

H106341

H10649

3

4

5

H10650

4

76

REAR SUSPENSION


Rear swinging arm removal- Position a suitable support under the engine and fasten the bike so that it

does not move.- Remove the wheel and the chain mudguard as described in the relevant

paragraphs.- Loosen the nut (1) and remove the pin (2) by slightly lifting the swinging

arm.

- Detach the support (3) with the calliper from the swinging arm (4) and remove the clamp (5) by loosening the related screw.

- Loosen the nut (6) on the left side keeping the pin (7) steady on the right side; then remove the pin (7) and the swinging arm (4).

J.9

NUDA 900 2012 - NUDA 900 R 2012

H10651

2

1

H10652

2

H106533

H10654

4

H106555


REAR SUSPENSION

Chain upper slide removal- Position a suitable support under the engine and fasten the bike so that it

does not move.- Remove the wheel and the sprocket casing as described in the relevant

paragraphs.- Loosen the screw (1) and remove the sprocket (2).

- Loosen the upper screw (3) and the lower screw (4) keeping the valve spring retainers.

- Remove the slider (5) toward the front side of the bike and replace it.

J.10

NUDA 900 2012 - NUDA 900 R 2012

H10656

1

H10657

2

H10658

2

REAR SUSPENSION


Chain lower slide removal- Loosen the screw (1), turn the slider (2) and remove it downwards.

L.1

NUDA 900 2012 - NUDA 900 R 2012

L


BRAKES

Section

L.2

NUDA 900 2012 - NUDA 900 R 2012

BRAKES


Braking system ............................................................................................. L.3Brake disc ..................................................................................................... L.5Rear braking system removal ....................................................................... L.6Front braking system removal ...................................................................... L.8Checking brake pads for wear / replacing the pads ................................... L.10Brake fluid replacement .............................................................................. L.13Fluid replacement and system bleeding ..................................................... L.13Front braking system .................................................................................. L.13Rear braking system................................................................................... L.14Front braking system bleeding ................................................................... L.15Rear braking system bleeding .................................................................... L.17

L.3

NUDA 900 2012 - NUDA 900 R 2012

H10847

1

2

3

H10848

4

57

H10849

8

6


BRAKES

Braking systemThe braking system uses two independent circuits. Each circuit is equipped with a brake calliper connected to a master cylinder with a fluid reservoir.

1. Front brake lever2. Front master cylinder3. Front oil reservoir4. Front line5. Right-hand front brake calliper6. Left-hand front brake calliper7. Right-hand front brake disc8. Right-hand front brake disc

L.4

NUDA 900 2012 - NUDA 900 R 2012

H10850

9

10

13 14

H10851

12

11

BRAKES


9. Rear brake fluid reservoir10. Rear line11. Rear brake calliper12. Rear brake disc13. Rear master cylinder14. Rear brake control pedal

L.5

NUDA 900 2012 - NUDA 900 R 2012

H10852

H10853

H10854


BRAKES

Brake discChecking the brake disc is an important safety procedure; the disc must be spot-less, i.e. free from corrosion, oil or other dirt or deep scoring.

Front brake disc diameter: mm 320 (12.6 in.).

Front brake disc thickness (when new): mm 4.5 (0.177 in.).

Minimum disc thickness (wear limit): mm 4 (0.157 in.).

Rear brake disc diameter: mm 265 (10.43 in.).

Rear brake disc thickness (when new): mm 5 (0.2 in.).

Minimum disc thickness (wear limit): mm 4.5 (0.177 in.).

The distortion of the discs must not exceed 0.15 mm (0.006 in.) (the measurement should be made with a feeler gauge and a disc installed on the rim).To remove the disc from the wheel rim, you need to loosen the five retaining screws. On assembly, clean all mating surfaces thoroughly and tighten the screws to the specified torque.

During the removal/replacement of the discs, replace the retaining screws!

L.6

NUDA 900 2012 - NUDA 900 R 2012

H10855

12

13

H10856

3

45

H10857

6

7

BRAKES


Rear braking system removal- Remove the rear wheel (1) and the chain/mudguard casing (2) as described

in the relevant paragraph.

- Unhook the spring (3), loosen the three screws (4) and remove the cover (5), so the master cylinder is free.

- Loosen the screw (6) and remove the oil reservoir (7).

L.7

NUDA 900 2012 - NUDA 900 R 2012

H10858

8

9

10

11

12

13

H10927

14

15

16

1718

H10928

14

15

16 1718


BRAKES

- Loosen the screw (8) and remove the cable ring (9).- Cut the clamps that fasten the system.- Loosen the screw (10) and remove the speed sensor (11).- Remove the calliper (12) with the whole system.

- In case you need to replace the master cylinder (14), open the clamp (15) and detach the pipe (16) collecting the oil that comes out of the reservoir, then loosen the coupling (17) and remove the delivery pipe (18).

During the reassembly, position the pipe (13) of the rear brake exactly in the original position and fasten it with the relevant clamps and cable ring. Lock the pipe in position with the rear casing/mudguard and then, if the braking system was disassembled, fill the oil and bleed the system as described in the relevant paragraph.

L.8

NUDA 900 2012 - NUDA 900 R 2012

H10859

1

2

H10860

5

3

4

H10861

6

7

8

9

H10862

6 7

89

BRAKES


Front braking system removalTo remove the front braking system from the vehicle, you must separate the various components; then you should empty the liquid from the system as fol-lows:- Remove the rubber cap (1) of the coupling (2) of one of the two callipers.

- Insert a transparent hose in the coupling and the other end of the hose in a container.

- Remove the cover (3) with the respective gaiter of the oil reservoir (4).

- Pull the brake lever (5) and keep it pulled, loosen the coupling (2) and wait for the oil to come out, then tighten the coupling (2) and release the lever (5).

- Repeat this procedure a few times both for the left and the right calliper, until the oil is completely drained.

- Loosen the couplings (6) and detach the pipes (7).

- Loosen the screws (8) and remove the callipers (9) making sure to collect the liquid that could remain inside pipe.

Do not spill brake fluid onto any painted surface or lens (for example lights lens).



L.9

NUDA 900 2012 - NUDA 900 R 2012

H10930

13

12

12

H10929

10

11


BRAKES

- Loosen the drilled bolt (10) and disconnect the brake pipe (11) from the mas-ter cylinder.

- Loosen the two screws (12) and remove the full lever (13).

During the reassembly, position the front brake pipe in the original position with the respective clamps, then pour the oil in the reservoir and bleed the system as described in the relevant paragraph.

L.10

NUDA 900 2012 - NUDA 900 R 2012

H10864

1

21

1

1

1

12

16

1

A

H10865

1

H10866

2

H10867

2 3

BRAKES


Checking brake pads for wear / replacing the padsCheck brake pad wear.Service limit ”A” - 4 mm - (0.157 in.) (front and rear pads)

If said limit has been exceeded, or if even only one of the wear indicators is no longer visible, replace the pair of pads (in any case, the replacement is neces-sary when the wear indicators are no longer visible).Be careful that no brake fluid or any oil gets on brake pads or discs. Clean off with alcohol any fluid or oil that inadvertently gets on the pads or disc.Replace the pads with new ones if they cannot be cleaned satisfactorily.

DISASSEMBLY OF THE REAR PADS- Remove the safety clip (1).- Slide out pin (2).- Remove the pads (3) making sure not to damage the pre-load clip inside the

calliper.

Do not use the brake pedal while removing the pads.

ASSEMBLY OF THE REAR PADS- Install new brake pads.- Reassemble the pin (2) making sure not to damage the pre-load clip inside

the calliper and the safety clip (1).

Acting as described above, after replacing the pads it is not necessary to bleed the system, just act the control lever several time until the pistons get in the normal position.

L.11

NUDA 900 2012 - NUDA 900 R 2012

H10868

12

H10869

3

H10870

4

5

H10871

6


BRAKES

REPLACEMENT FRONT BRAKE PADS NUDA 900- Loosen the two screws (1) and remove the calliper (2).

- Remove the two safety clips (3).

- Slide out the two pins (4) and remove the metal sheet (5).

- Replace the brake pads (6).

Do not use the brake lever while removing the pads.

NOTE: Refit the metal sheet (5) so that the arrow points in the direction of rotation of the brake disc.

- Refit the pins and the safety pins.- Refit the calliper tightening the screws (1) to the specified torque.

NOTE: During the reassembly of the callipers, first of all insert the retain-ing screws manually then, before tightening them to the specified torque, keep the lever of the front brake pulled, for instance with an elastic. Only at this point, tighten the retaining screws of the callipers to the specified torque.

This ensures the correct positioning between the brake disc and the body of the calliper, avoiding thus that the pistons work incor-rectly.

L.12

NUDA 900 2012 - NUDA 900 R 2012

H10931

1

2

H10932

3

H10933

4

H10934

3

BRAKES


FRONT BRAKE PAD REPLACEMENT - NUDA 900 R- Loosen the screws (1) and remove the calliper (2).

- Prize with a screwdriver in order to remove the pads (3) from the seat (4) in the body of the calliper.

- Replace the pads (3).

Do not use the brake lever while removing the pads.

- Refit the pads (3) making sure that they are correctly inserted in the seat (4) in the body of the calliper.

NOTE: During the reassembly of the callipers, first of all insert the retain-ing screws manually then, before tightening them to the specified torque, keep the lever of the front brake pulled, for instance with an elastic. Only at this point, tighten the retaining screws of the callipers to the specified torque.


L.13

NUDA 900 2012 - NUDA 900 R 2012

H10859

1

2


BRAKES

Brake fluid replacementFor the replacement of the braking system fluid, first of all you need to drain the existing fluid.

Fluid replacement and system bleedingBrake fluid should be checked and changed as per the "Maintenance Chart" (see Section B), or earlier if contaminated with debris or water.

Do not change brake fluid in the rain or with a strong wind.

Use only fluid taken from a sealed container (DOT 4). Never reuse brake fluid.

Avoid the ingress of contaminants such as dirt, water, etc. into the reservoir.

Do not keep the reservoir open without its cover longer than neces-sary; this would increase the risk of contamination.

Handle the fluid with care to avoid damaging the painted parts.

Do not mix two brands of fluid. This would reduce boil-over point, leading to loss of braking efficiency or degrading of rubber parts.

Front braking system- Remove the rubber cap (1) of the valve (2) of one of the two callipers.- Insert the end of a transparent hose in the valve (2) and the other end in a

container.

L.14

NUDA 900 2012 - NUDA 900 R 2012

H10860

5

3

4

H10872

12

H10873

4

3

H10874

5

BRAKES


- Remove the cover (3) with the respective gaiter of the oil reservoir (4).- Pull the lever (5) of the brake and keep it pulled, loosen the valve (2) and

wait for the oil to come out, then tighten the valve (2) and release the lever (5).

- Repeat this procedure a few times both for the left and the right calliper, until the oil is completely drained.

- Fill the reservoir (4) with the new fluid.- Pull the lever (5) of the brake and keep it pulled so that the system remains

under pressure, loosen the valve (2), tighten the valve (2) always with the lever pulled, then release the lever.

- Top up the fluid level (4) and repeat a few times the procedure described in the line above until the system is completely full and the clear fluid begins to come out without bubbles from the transparent hose.

- Repeat the same procedures for the other calliper.- Top up the fluid level (4) and refit the cover (3) with the gaiter.

After replacing the fluid, bleed the system on both callipers and on the master cylinder as described in the relevant paragraph.

Rear braking system- Remove the rubber cap (1) of the valve (2) of the calliper.- Insert the end of a transparent hose in the valve (2); insert the other end in

a container.- Remove the cover (3) with the respective gaiter of the oil reservoir (4).- Press on the brake pedal (5) and hold it pressed, loosen the valve (2) and

wait for the oil to come out, then tighten the valve (2) and release the pedal (5).

- Repeat this procedure a few times until the oil is completely drained.- Fill the reservoir (4) with new liquid.- Press on the brake pedal (5) and hold it pressed so that the system is under

pressure, loosen the valve (2), tighten the valve (2) always with the pedal pressed, then release the pedal.

- Top up the fluid level (4) and repeat a few times the procedure described in the line above until the system is completely full and the clear fluid begins to come out without bubbles from the transparent hose.

- Top up the fluid level (4) and refit the cover (3) with the gaiter.

After replacing the fluid, bleed the system as described in the rel-evant paragraph.

L.15

NUDA 900 2012 - NUDA 900 R 2012

H10875

1

H10876

2

H10877

1A

2A


BRAKES

Bleeding the front braking systemA long travel and mushy feel of the brake lever indicate that there is air in the system and the brake needs bleeding. Bleeding is also required after changing brake fluid.To bleed the front braking system, begin with the master cylinder fastened on the handlebar, then on the on the calliper: the procedure is the same.Proceed as follows.- Take the rubber cover off the bleed valve (1) or (1A).

- Insert the end of a transparent hose in the valve (2) or (2A) and the other end in a container with fluid (make sure that the hose is constantly immersed in the fluid).

L.16

NUDA 900 2012 - NUDA 900 R 2012

H10860

5

3

4

BRAKES


- Remove the cover (3) of the fluid reservoir (4), the rubber gaiter and fill the reservoir with fresh fluid.

- Pull the lever (5) of the brake and keep it pulled so that the system remains under pressure, loosen the valve (2), tighten the valve (2) always with the lever pulled, then release the lever.

- Top up the fluid level (4), wait a few seconds, then repeat a few times the procedure described in the line above until the liquid comes out of the trans-parent hose without bubbles.

- Lock the bleed valves to the specified torques.

- Top up the fluid level and refit the rubber gaiter and the cover (3) of the res-ervoir (4).

Fluid level inside the reservoir shall never drop below the minimum notch during the bleeding procedure.

Brake fluid is corrosive. In the event of contact with eyes, rinse with abundant water.

Motorcycle handlebar must be turned to the left during the bleed-ing procedure. This will keep the master cylinder reservoir higher, making bleeding easier.

If brake lever or brake pedal feel mushy after a fall or after a repair, resulting in loss of braking, bleed the circuit as described above.

L.17

NUDA 900 2012 - NUDA 900 R 2012

H10878

2

1

H10879

34

H10874

5


BRAKES

Bleeding the rear braking systemA long travel and mushy feel of the brake pedal indicate that there is airin the system and the brake needs bleeding.Bleeding procedure is as follows:- Remove the cover (1) of the fluid reservoir (2), the rubber gaiter and fill the

reservoir with fresh fluid.

- Remove the rubber cap (3) on the bleed valve (4).

- Insert the end of a transparent hose in the valve (4) of the calliper; insert the other end in a container.

- Press the pedal (5) fully down.

- With the brake pedal (2) down, loosen the bleed valve (4) so that the fluid comes out of the hose (at the beginning only air will come out), then close the valve (4).

- Release the pedal and wait a few seconds. Repeat the process until you see only fluid without bubbles coming out of the hose.

- Tighten the bleed valve to the specified torque and check fluid level (2) in the reservoir before refitting the cap (1). If the bleeding procedure was performed correctly, the pedal will no longer have that mushy feel. If not so, repeat the procedure.

Fluid level inside the reservoir shall never drop below the minimum notch during the bleeding procedure.

Brake fluid is corrosive. In the event of contact with eyes, rinse with abundant water.

If brake lever or brake pedal feel mushy after a fall or after a repair, resulting in loss of braking, bleed the circuit as described above.

L.18

NUDA 900 2012 - NUDA 900 R 2012

H10880

C

H10881

D

BRAKES


Periodically check the connecting hoses (C) and (D) (see Scheduled Maintenance Chart, Section B): if they show signs of wear or damage, replace them.

M.1

NUDA 900 2012 - NUDA 900 R 2012

M


ELECTRICAL SYSTEM

Section

M.2

NUDA 900 2012 - NUDA 900 R 2012

ELECTRICAL SYSTEM


Wiring diagram ............................................................................................ M.5Electrical components location .................................................................... M.8Generator stator windings resistance test ................................................. M.12Generator performance ............................................................................. M.12Gear position sensor ................................................................................. M.13Crankshaft position sensor ........................................................................ M.13Ignition and injection system ..................................................................... M.14Charging system........................................................................................ M.15Charging system inspections..................................................................... M.16Battery ....................................................................................................... M.16Regulated voltage...................................................................................... M.16Voltage regulator inspection ...................................................................... M.16Voltage regulator ....................................................................................... M.16Voltage regulator/rectifier wiring diagram .................................................. M.16Electrical starting system ........................................................................... M.17Starting system inspections ...................................................................... M.18Starter motor inspection ............................................................................ M.18Starter motor ............................................................................................. M.18Solenoid starter inspection ........................................................................ M.18Starter relay wiring diagram ...................................................................... M.18Coil windings resistance / Stick-Coil test ................................................... M.19Electronic control unit (ECU) ..................................................................... M.19Spark plug ................................................................................................ M.20 Battery ....................................................................................................... M.20Battery charger .......................................................................................... M.20Reference values related to the duration of the charge depending on status of the battery ............................................................................. M.20Headlight, tail light ..................................................................................... M.21Adjustment of headlight ............................................................................. M.21 Headlight replacement............................................................................... M.22Headlight removal...................................................................................... M.23Turning indicator bulb replacement ........................................................... M.24 Tail light replacement ................................................................................. M.24Number plate bulb replacement ................................................................ M.25Left-hand switch ........................................................................................ M.26Right-hand switch ...................................................................................... M.27Right-hand switch removal ........................................................................ M.28Left-hand switch removal........................................................................... M.29Fuses ......................................................................................................... M.30Semiconductor parts.................................................................................. M.31Relay removal............................................................................................ M.31Relay inspection ........................................................................................ M.32Combined dashboard ................................................................................ M.33Warning light description ........................................................................... M.34Multifunction display description ................................................................ M.35Clock adjustment ....................................................................................... M.35Setting units of measurement .................................................................... M.36Setting parameters .................................................................................... M.37Control unit removal .................................................................................. M.38Ignition removal ......................................................................................... M.39Combined dashboard replacement ........................................................... M.39Rear stop microswitch replacement .......................................................... M.40Clutch microswitch replacement ................................................................ M.40Front stop microswitch replacement .......................................................... M.41Speed sensor replacement........................................................................ M.41Stand rotating switch replacement ............................................................ M.4212V plug replacement................................................................................ M.42Water temperature sensor replacement .................................................... M.43Troubleshooting ......................................................................................... M.44Charging system........................................................................................ M.44

M.3

NUDA 900 2012 - NUDA 900 R 2012


ELECTRICAL SYSTEM

Starting system .......................................................................................... M.44Electronic ignition system .......................................................................... M.44Electrical connectors positioning ............................................................... M.45Important ................................................................................................... M.48

M.4

NUDA 900 2012 - NUDA 900 R 2012

ELECTRICAL SYSTEM


NUDA 900 2012 - NUDA 900 R 2012

M.5

H10467

567810222324252627

21

14 9

28

29

30

31

32

33

34

35

36

37

3839 40 41 42 44 45 47

46

43

48

5049 51

5253

54

55

1

2

3

4

13

1112

1815 16

17 19 20


ELECTRICAL SYSTEM

Wiring diagram

M.7

NUDA 900 2012 - NUDA 900 R 2012


ELECTRICAL SYSTEM

Key to wiring diagram 1) Control unit ECU2) Diagnostic connector3) DWA (Can Resistor)4) 12V current plug5) Alternator6) Voltage regulator7) Battery8) Solenoid starter9) Starter motor10) Coolant temperature sensor11) Horn12) Fuse box13) 7.5 A fuse Engine control Diagnosis Starter relay control Brake light Parking lights (Heated hand grips)14) 15 A fuse Headlights Number plate light Horn Turning indicators Instrument panel15) 15 A fuse Left-hand cylinder injector Left-hand cylinder ignition16) 15 A fuse Right-hand cylinder injector Right-hand cylinder ignition Exhaust valve Lambda sensor17) 15 A fuse Radiator fan Fuel pump18) 15 A fuse Engine control Diagnosis Instrument panel Battery socket (Alarm system)19) 15 A fuse replacement20) 7.5 A fuse replacement21) Air temperature sensor22) Speed adjustment valve23) EFI general relay24) Electric fan relay25) Fuel pump relay26) Radiator electric fan27) Ignition28) Transponder antenna29) Connector for heated hand grips kit (Optional)30) Right-hand switch31) Front brake lever stop microswitch32) Combined dashboard33) Front R.H. turning indicator34) Headlight35) Front L.H. turning indicator

36) Clutch control lever37) Right-hand switch38) Throttle opening position sensor39) Injector 140) Injector 241) Coil / spark plug 142) Coil / spark plug 243) Engine ground terminal44) Gear position sensor45) Crankshaft position sensor46) Fuel pump47) Rear brake pedal stop microswitch48) Side stand microswitch49) Exhaust valve actuator50) Speed sensor51) Lambda sensor52) Rear L.H. turning indicator53) Number plate light54) R.H. turning indicator55) Tail light

Colour keyblge ............... blue / yellowblgn ............... blue / greenblrt................. blue / redblsw .............. blue / blackbr .................. brownbl ................... bluebrge .............. brown / yellowbrgr ............... brown / greybrsw .............. brown / blackbrvi ................ brown / purplebrws .............. brown / whitegebl ............... yellow / bluegebr .............. yellow / browngegn.............. yellow / greengert ............... yellow / redgnbl ............... green / bluegnge.............. green / yellowgngews ......... green / yellow / whitegnsw ............. green / blackgrvi ................ grey / purpletrt .................. redrtbl................. red / bluertgn ............... red / greenrtws ............... red / whitesw ................. blackswgn ............. black / greenswrt ............... black / redwsbl .............. white / bluewsbr .............. white / brownwsge ............. white / yellowwsgn ............. white / greenwsrt ............... white / redwssw ............. white / blackwsvi ............... white / purple

M.8

NUDA 900 2012 - NUDA 900 R 2012

H10468

1

H10469

2

H10470

3

H10471

4

ELECTRICAL SYSTEM


Electrical component location- Generator (1) inside the right-hand cover;

- Electronic ignition coils (2) integrated with spark plug cap positioned on the cylinder head;

- Spark plugs on the cylinder head;

- Electronic control unit (3) on the front part in front of the filter box;

- Voltage regulator (4) on a support on the battery;

M.9

NUDA 900 2012 - NUDA 900 R 2012

H10472

5

H10473

6

H10474

7

H10475

89


ELECTRICAL SYSTEM

- Starter motor (5) on the front part of the engine;

- Starter relay (6) on the central part behind the battery;

- Throttle opening position sensor (7) on the throttle body;

- Fuel pump (8) inside the reservoir (9);

M.10

NUDA 900 2012 - NUDA 900 R 2012

H10476

10

H10477

11

H10478

1213

14

H10479

15

ELECTRICAL SYSTEM


- Battery (10) 12V - 12Ah on the central part of the right-hand side;

- A 30A fuse (11) on the solenoid starter;

- Relays on the front side near the control unit: - Relay (12): main; - Relay (13): electric fan; - Relay (14): fuel pump.

- Coolant temperature sensor (15) on the rear part of the cylinder head.

M.11

NUDA 900 2012 - NUDA 900 R 2012

H10480

16

H10483

20

H10572

19

17

H10573

18

19


ELECTRICAL SYSTEM

- Electric fan (16) on the rear part of the radiator.

- Headlamp (17) with H4 12V-55/60W twin halogen lamp and 12V-5W parking light bulb;

- LED tail light (18);- Turning indicators (19), 12V-6W bulbs;

- Combined dashboard (20);

M.12

NUDA 900 2012 - NUDA 900 R 2012

H10468

1

H10484

2

ELECTRICAL SYSTEM


Checking generator stator windings resistance (1)Disconnect the stator coil connector from the wiring and measure resistance with a meter.

1) Measure across the terminals of the connector (2); correct value is about 0.1 - 1.0 .

If resistance is outside the specified limits, replace the complete generator.

Generator performance:12V / MAX 390W.

AT EACH ENGINE OVERHAUL, CLEAN FLYWHEEL ROTOR TO REMOVE ANY DEBRIS SUSPENDED IN SWIRLING OIL AND CAP-TURED BY THE MAGNETS.

M.13

NUDA 900 2012 - NUDA 900 R 2012

H10935

H10937


ELECTRICAL SYSTEM

Gear position sensorPositioned in the left-hand side of the engine, under the sprocket casing.

Crankshaft position sensorPositioned on the rear right-hand side of the engine.

M.14

NUDA 900 2012 - NUDA 900 R 2012

1

234

56

7

8

9

10 12 13

14

11

H10939

ELECTRICAL SYSTEM


Ignition and injection systemThe engine ignition and injection system is controlled by the electronic control unit (ECU) which controls the status of the engine and the surrounding environ-ment at each moment with a series of sensors.The sensors are: a crankshaft position sensor (pick-up), an ambient air tempera-ture sensor in filter box, a coolant temperature sensor, a throttle position sensor and a pressure sensor on the throttle body.

The ignition system is composed of:- ECU (1).- Battery (2).- Starter relay (3).- Fuse box (4).- EFI general relay (5).- Ignition (6).- Transponder antenna (7).

- R.H. switch (8).- Clutch lever microswitch (9).- Spark plug coils (10).- Engine ground terminal (11).- Gear position sensor (12).- Crankshaft position sensor (13).- Side stand microswitch (14).

M.15

NUDA 900 2012 - NUDA 900 R 2012

H10940

1 2 3


ELECTRICAL SYSTEM

Charging systemThe charging system is composed of:- Battery (1);- Voltage regulator (2);- Alternator (3).

The alternated current generated by the alternator is converted into direct cur-rent by the voltage regulator. The voltage regulator serves a dual purpose: it provides overvoltage protection for the battery and converts alternated current into direct current.

M.16

NUDA 900 2012 - NUDA 900 R 2012

H10485

1

H10486

1

H10941

YYY

R/W

GR

R/W

YYY

GR

Hy - IC

FUSE

BATTLOAD

ELECTRICAL SYSTEM


Charging system inspections

BatteryRemove the protection panel (as described in the relevant paragraph) to gain access to the battery (1).Disconnect the BLACK negative cable from the battery.Measure current across the negative terminal of the battery and the negative cable using an ammeter clamp. A reading greater than 0.5 mA indicates current draw by some utility.

If the vehicle is not used for long periods, it is recommended to disconnect the battery from the electrical system.

Regulated voltageRemove the protection panel (as described in the relevant paragraph) to gain access to the battery.With the engine warmed up and running at slightly above 3,000 rpm, measure voltage across the positive and negative terminal of the battery using a meter (the battery must be charged when performing this test). If reading is outside a 14.0÷14.5 V, check generator and voltage regulator as described in the relevant paragraph.

Voltage regulator inspectionWith the ignition on and the battery charged (12.5-13 V), start the engine: if the battery voltage does not increase (14 V) after around two minutes, it is neces-sary to check the voltage regulator as well as the battery.

Voltage regulatorThe voltage regulator (1) incorporates the diodes used to rectify the generator current output.It also incorporates an electronic device that adjusts charging voltage to battery charge: if battery charge is low, charging voltage will be lower.

Do not disconnect the battery cables while the engine is running, or the regulator will suffer irreparable damage.

Voltage regulator/rectifier wiring diagramKey:Y= YellowGR= GreenR/W= Red / WhiteLOAD= GroundFUSE= FuseBATT= Battery

Generator

M.17

NUDA 900 2012 - NUDA 900 R 2012

H10942

3

1

23

4

56

7

8

9

10 11


ELECTRICAL SYSTEM

Electric starting systemThe starting system is composed of:- ECU (1).- Battery (2);- Starter relay (3);- Starter motor (4);- Fuse box (5);- Ignition (6);- Transponder antenna (7).- R.H. switch (8);- Clutch lever microswitch (9).- Gear position sensor (10).- Side stand sensor (11).

M.18

NUDA 900 2012 - NUDA 900 R 2012

H10487

1

2

3

H10484

A

��

��

��

ELECTRICAL SYSTEM


Starting system inspection

Starter motor inspectionFor the inspection of the starter motor (1), proceed as follows:- connect a meter across ground (3) and starter motor contact (2).- Check for continuity between the positive pole and motor ground. If no continuity is found, replace the starter motor.

Starter motor Rated voltage: 12VCurrent draw: 900W

Solenoid starter inspectionDisconnect the cables at the battery negative terminal to avoid possible short circuits during disassembly. Disconnect the starter relay connector (A). Disconnect the starter motor and battery positive cable wires at relay end. Ap-ply 12 Volts to the terminals (1) and (2) on the relay and check the continuity between the terminals B-M. Do not apply such voltage to the relay for more than 5 seconds as it could overheat and suffer damage. Use a multimeter to establish whether the winding is open circuit or resistance exists. A winding in good condition will give the following resistance readings.Meter scale setting: OhmStarter relay resistance. Standard: 3-6 .

NOTE:If the fuse on the starter relay is interrupted or removed, the system is isolated from all electric supply sources.

Starter relay wiring diagram 1= 30A fuse2= + 12V to the starter motor

M.19

NUDA 900 2012 - NUDA 900 R 2012

H10489

1

2

H10492

1

H10493

3 2

1

1

2

3 4

2

H10943


ELECTRICAL SYSTEM

Coil windings / Stick-Coil inspection- Disconnect the connector (1).- Lift the coil / Stick-Coil (2) to remove it.- Measure the resistance of the primary and secondary winding with a me-

ter.

- Primary winding resistance: < 0.87 at 20°C.

WIRING DIAGRAM

1) PIN 1 ................. Vcoll2) PIN 2 .............Ground3) PIN 3 .................Vbatt4) High Voltage

Electronic control unit (ECU)Remove the filter box (see Chapter E) to gain access to the electronic control unit (1).The control unit consist of a microprocessor system that controls the ignition advance according to the signals coming from the various sensors, in accord-ance to the injection parameters.

M.20

NUDA 900 2012 - NUDA 900 R 2012

H10485

1

ELECTRICAL SYSTEM


Spark plug Check electrode gap "A" (0.8 ÷ 0.9 mm) (0.0315 ÷ 0.0354 in.). A wider gap may cause difficulties in starting the engine and overload the coil. A gap that is too narrow may cause difficulties when accelerating, when idling or poor perform-ance at low speed. Clean off any dirt around spark plug base before removing the spark plug. It is good practice to closely inspect the spark plug after removal, as any deposits on it and the colour of the insulator provide useful indications on spark plug heat rating, carburetion, ignition and the general condition of the engine. Before refitting the spark plug, accurately clean the insulator with a wire brush. Smear some graphite grease on spark plug thread, do it fully home finger tight then tighten it to 11 Nm - 1.1 Kgm - 8.11 ft/lb. Loosen the spark plug then tighten it again to 11 Nm - 1.1 Kgm - 8.11 ft/lb. Spark plugs which have cracked insulators or corroded electrodes should be replaced.

BatteryThe battery (1) is a sealed-for-life, maintenance-free battery. If the vehicle remains unused for long periods, it is recommended to disconnect the battery from the electrical system and store it in a dry place. After an intensive use of the battery, it is advisable to carry out a standard slow charging cycle (0.6A for 8 hours for 12V-12Ah battery).Quick charging is advised only in situations of extreme necessity since the life of lead elements is drastically reduced by such cycle (6A for 0.5 hours for 12V-12Ah battery).

Battery chargerTo gain access to the battery (1):- remove the protection panel (as described in the relevant paragraph);- first remove the BLACK negative cable, then the RED positive cable (when reassembling, first connect the RED positive cable, then the BLACK negative cable);- remove the battery (1) from its housing.Use a voltmeter to ensure that the battery voltage is not lower than 12.5V. If it is not so, the battery needs to be charged. Using a battery charger with a constant voltage, first connect the RED positive cable to the battery positive terminal then the BLACK negative cable to the battery negative terminal. At a constant voltage level of 14.4 V, apply “x” Amps according the battery's charge percentage as indicated in the table below. The voltage reaches a constant value only after a few hours, therefore it is suggested NOT to measure it immediately after hav-ing charged or discharged the battery. Always check the battery charge before reinstalling it on the vehicle. The battery should be kept clean and the terminals coated with grease.

INDICATIVE CHARGE TIMES DEPENDING ON BATTERY CHARGE STATUSAT REST VOLTAGE * (V) % CHARGE CHARGE DURATION (THE RATED CURRENT IN AMPERE

TO BE APPLIED: 0.1x BATTERY RATED CAPACITY)> 12.7~ 12.5~ 12.2~ 12.0~ 11.8

1007550250

_4h7h11h14h

M.21

NUDA 900 2012 - NUDA 900 R 2012

H1049410m/32,8ft

9__10X X

H10495

1

H10496

2


ELECTRICAL SYSTEM

Headlight, tail light

Headlight adjustmentThe headlamp features a twin bulb for low and high beam and a festoon bulb for the city or parking light.

When checking the proper aiming of the headlight beam: inflate tyres at the right pressure, have a person sit astride the motorcycle and set the motorcycle perpendicular to its longitudinal axisIn front of a wall or a screen positioned at a distance of 10 metres (32.8 ft), draw a horizontal line corresponding to headlight centre height, and a vertical line aligned with vehicle longitudinal axis.

If possible, execute this operation in a shaded place.When the low beam is on, the upper edge between dark and lit zone should be at 9/10th of headlight centre from ground.Beam height can be adjusted as follows:

- Turn the adjuster screw (1) on the left side of the headlight unit; tighten to lower the beam, loosen to raise the beam.

- Turn the adjuster screw (2) on the right side of the headlight to adjust the beam horizontally.

M.22

NUDA 900 2012 - NUDA 900 R 2012

H10497

1

H10498

1

H105003

4

H10501

5

H10504

8

9

H105037

6

H10499

2

H10961

5

10

ELECTRICAL SYSTEM


FRONT HEADLAMP BULB REPLACEMENTProceed as follows to reach the headlamp bulbs:- Undo the two upper screws (1);- lift the headlight assembly by releasing it from the lower clips (2);- release connector (3);- slide off the rubber gaiter (4);- turn the ring nut (5) counter-clockwise until the bayonet fitting is released; then

remove it;- remove the bulb (10).

Headlamp bulb (10) is of the halogen type; be careful when replac-ing it since the glass part shall not be touched with bare hands.

Make sure that the new bulb is of the HD type (Heavy Duty).

To replace the parking light bulb:- Loosen the two screws (6) and remove the cover (7);- Detach the bulb holder (8) and remove the light bulb (9).

Make sure that the new bulb is of the LL type (Long Life).Once the bulb has been replaced, reverse the above procedure to reassem-ble.

M.23

NUDA 900 2012 - NUDA 900 R 2012

H10505

1

1

H10944

5

H10506

3

3

2

H10507

4


ELECTRICAL SYSTEM

Headlight removal

- Remove the tool as described in the relevant paragraph.- Remove all connectors.- Loosen the two front screws (1).

- Unhook the clutch cable (2) from the fastening.- Unhook the front brake pipe from the fastening.- Loosen the two upper screws (3) and lift the support (4) with the turning indica-

tors.

- Move forward the upper part of the light (5), then lift it unhooking it from the supporting pins.

During the reassembly, reattach both the front brake pipe and the clutch cable, after fastening the light.

M.24

NUDA 900 2012 - NUDA 900 R 2012

H10509

1

2

3H10574

ELECTRICAL SYSTEM


Turning indicator bulb replacement

- Loosen the screw (1);

- remove lens (2) and replace bulb (3) pushing it inside, and turning it to remove it;

Once the bulb has been replaced, reverse the above procedure to reassem-ble.(12V - 6W bulb)

Make sure that the new bulb is of the LL type (Long Life).

Tail light replacementThe tail light (1) is a LED light; if it does not work properly, it must be replaced.The removal of the tail light is described in Chapter "E".

M.25

NUDA 900 2012 - NUDA 900 R 2012

H10510

1

2

H10511

3

4


ELECTRICAL SYSTEM

Number plate bulb replacement- Loosen screw (1) and remove the number plate bulb (2) from the mudguard.

- Extract the bulb holder (3) with the bulb (4) from the housing.- Pull the bulb (4) to detach it from bulb holder.

Once the bulb has been replaced, reverse the above procedure to reassem-ble.(12V - 5W bulb).

Make sure that the new bulb is of the LL type (Long Life).

M.26

NUDA 900 2012 - NUDA 900 R 2012

H10512

2

34

1

AZ/GR

AZ/N

BL/B

G/N

B/BL

B/BL

V/N

V/N

V

V/A

1234

12345

H10946

H10945

TURN SWITCH HORN SWITCHAZ/R V/BL V/GRBL/B AZ/N CARICO

NOMINALECARICO

NOMINALE

52 W

52 W

PREMUTO (OFF)N

A RIPOSO (OFF)

PREMUTO (ON) 60 W

DIMMER SWITCH PASSING SWITCHV/M B/V V/M G/V/N CARICO

NOMINALE

HI 80W80W 80WLO

V/BL B/V CARICO NOMINALE

A RIPOSO (OFF)

PREMUTO (ON)

ELECTRICAL SYSTEM


Left-hand switch

1. High beam flashing light

2. High beam switch control

Low beam switch

3. Left-hand turning indicators (self-cancelling)

Right-hand turning indicators (self-cancelling)To deactivate the turning indicators, press the control lever after it is returned to the centre.

4. Horn.

- Turn Switch= Turn Switch- Premuto (OFF)= Pressed (OFF)- Horn Switch= Horn Switch- Carico nominale= Rated charge- A riposo (OFF)= At rest (OFF)- Premuto (ON)= Pressed (ON)- Dimmer switch= Dimmer switch- Passing switch= Passing switch

KeyAZ ................. Light blueGr .................. GreyN ................... BlackBl .................. BlueB ................... WhiteG ................... YellowV ................... GreenA ................... OrangeR ................... RedM ................... Brown

M.27

NUDA 900 2012 - NUDA 900 R 2012

H10513

2

1

H10947

< <

V

V/BL

V/BL

N/G


ELECTRICAL SYSTEM

Right-hand switch1. Engine start button2. Engine start/stop switch

KeyV ................... GreenBl .................. BlueN ................... BlackG ................... Yellow

M.28

NUDA 900 2012 - NUDA 900 R 2012

H10514

1

H10515

2

H10516

4

3

H10517

4

5

ELECTRICAL SYSTEM


Right-hand switch removal- Remove the tool as described in the relevant paragraph.- Loosen the screws (1) and move the lever/master cylinder.

- Disconnect the connector (2).

- Loosen the front screw (3) and turn the switch (4); loosen the screw (5), then remove the switch (4).

M.29

NUDA 900 2012 - NUDA 900 R 2012

H10518

12

H10519

4

3


ELECTRICAL SYSTEM

Left-hand switch removal- Remove the tool as described in the relevant paragraph.- Disconnect the two connectors (1) and (2).

- Loosen the two screws (3) and remove the light switch (4).

M.30

NUDA 900 2012 - NUDA 900 R 2012

H10520

2

1

H10521

H105223

ELECTRICAL SYSTEM


Fuses• When you find a blown fuse, always investigate and eliminate the cause

before replacing it.• Never replace a fuse with another fuse with a different rating.• Never use a wire or other makeshift repair techniques instead of installing

a new fuse.

General fuse (1) - 30ATwo fuses located in the rear of the battery compartment on the solenoid starter, one of which is a spare.1= General fuse.2= Spare fuse.

Auxiliary fuses (3)Located at the rear of the motorcycle under the saddle.Fuse 1 = 7.5 A Engine control Diagnosis Starting relay Brake light Parking lights (Heated hand grips)Fuse 2 = 15 A Headlights Number plate light Horn Turning indicators Instrument panelFuse 3 = 15 A Left-hand cylinder injector Left-hand cylinder ignitionFuse 4 = 15 A Right-hand cylinder injector Right-hand cylinder ignition Exhaust valve Lambda sensorFuse 5 = 15 A Radiator fan Fuel pumpFuse 6 = 15 A Engine control Diagnosis Instrument panel Battery socket (Alarm system)Fuse 7 = 15 A (Spare)Fuse 8 = 7.5 A (Spare)

To avoid possible short circuits, set the ignition switch to OFF before servicing the fuses.

Never use a fuse with a different rating.

M.31

NUDA 900 2012 - NUDA 900 R 2012

H06526

H10523

2

1

1

H10524

3

2


ELECTRICAL SYSTEM

Semiconductor parts• Be careful to never drop parts that incorporate a semiconductor, such as

the ECU or the voltage regulator/rectifier.• Closely follow the relevant instructions when inspecting these parts. An

improper procedure may lead to severe damage.

Relay removal- Remove the filter box cover as described in the relevant paragraph.- Loosen the two screws (1) and lift the relay support (2).- Remove the connectors from the relays (3) and remove the relays slipping

them off upwards.

M.32

NUDA 900 2012 - NUDA 900 R 2012

H10525

1

2

3

ELECTRICAL SYSTEM


Relay testGain access to the relays as described in the relevant paragraph; then remove them.

1) Main relay.2) Electric fan relay3) Fuel pump relay

A: Set the meter to the "Impedance" scale and check the energiser coil for proper operation. Reading should be: 80 Ohm (+/- 10%) at 20 °C.

B: Set the meter to "Continuity" mode and check the circuit is open.

C: Feed the coil from a power supply unit with stable 12V output and make sure that the circuit closes.

M.33

NUDA 900 2012 - NUDA 900 R 2012

H10526

1

324

5a

5b5

67 8 9


ELECTRICAL SYSTEM

COMBINED DASHBOARD

The motorcycle has a combined dashboard divided into the following areas:1. Warning lights (see “ Warning light description”).2. Multifunction display (see “ Multifunction display description”).3. Rev meter Indicates the engine rpm.4. Alarm system warning light (RED).5. Overrev warning lights (RED) When 8500 rpm is reached, warning light (5a) comes on. When 9000 rpm

is reached, warning light (5a) stays on together with warning light (5b).6. Engaged gear display This indicates the engaged gear; neutral is indicated with this symbol “ ”.7. “MODE” button Vehicle performance can be varied by selecting “RAIN” mapping. The ECU memorises two different mappings that can be selected using

the “MODE” button (see specific paragraph). The standard configuration delivers maximum engine power. The second

mapping delivers power than can be used more at low and medium revs and is suitable when using the vehicle on wet roads or low grip situations (see “Map change”).

8. “SET” button This displays the various functions of the multifunction display (see “Multi-

function display description”).9. “HAZARD” button When this is pressed, the turning indicators, warning light and warning

light flash at the same time. Press it again to deactivate the hazard warning lights.

M.34

NUDA 900 2012 - NUDA 900 R 2012

ELECTRICAL SYSTEM


Warning light description

ABS “ABS” warning light (not used).

Turning indicator warning light (GREEN) This flashes when the turning indicators have been turned on or the

“HAZARD” button has been pressed.

High beam warning light (BLUE) This lights up permanently when the high beam is on.

High coolant temperature warning light (RED). This lights up permanently when the coolant reaches the alarm tempera-

ture; Slow down until you come to a stop, let the engine idle and wait for the

temperature to decrease (scale shown on display) and the warning light to go out.

If the problem persists, check the coolant level in the expansion tank. If the liquid level is correct, contact your HUSQVARNA dealer.

Neutral warning light (GREEN) This lights up permanently when the motorcycle is in neutral.

Engine diagnosis warning light (ORANGE) This lights up permanently when the engine ECU has diagnosed mal-

functioning. There are two types of fault: - Critical fault: the engine switches off and you must contact your HUSQ-

VARNA dealer. - Fault with emergency operating: the engine operates with reduced

performance to allow you to reach the nearest HUSQVARNA dealer to have the fault checked.

“HAZARD” warning light (RED) This flashes together with the warning light and the turning indicators

when switch has been pressed.

Fuel reserve warning light (ORANGE) This comes on when there are approximately 3 litres of fuel left in the

tank.You need to refuel.

The fuel reserve warning light usually switches itself off after refuelling.

M.35

NUDA 900 2012 - NUDA 900 R 2012

H10527

12

3

4 56

78

H10528

1

H10529

> 4”

4”<


ELECTRICAL SYSTEM

Multifunction display description1. “ICE” indicator: This appears when the external temperature is lower than 3°C or 37.4°F2. “SERVICE” indicator: This indicates that it is time for a service. Contact your HUSQVARNA dealer to have scheduled maintenance work

carried out.3. “MAP II” indicator: This appears when “RAIN” mapping is selected4. km/h or mp/h odometer scale indicator (see “setting units of measure-

ment”)5. Speed indicator6. Display parameters: This field is used to individually set the parameters below that will be

displayed in (7). ODO = Odometer / Total mileage TRIP = Odometer / Partial mileage (to set the functions, see “Setting parameters”) TEMP = Air temperature (AIR BOX) / Coolant temperature CON = Actual fuel consumption / Average consumption. CLOCK = Clock ( see “Clock adjustment”).7. This displays the parameter set in the field (6).8. This lights up in sequence from left to right as the coolant temperature

increases.

Clock adjustmentThe clock must be set when the motorcycle is stationary and the key is set to ON.The clock is set to 24 hours.

- Press the “S” button (1) until the word “CLOCK” appears on the display.

- Press the “S” button for more than 4 seconds and the hours will flash on the display.

- The value of the hours increases by one unit each time you press the “S” button.

- The value of the hours decreases by one unit each time you press the “M” button.

- Press the “S” button for more than 4 seconds to memorise the hours set and the minutes will flash on the display.

- The value of the minutes increases by one unit each time you press the “S” button.

- The value of the minutes decreases by one unit each time you press the “M” button.

- To memorise the time once you have set it, press the “S” button for more than 4 seconds. If not, the setting is automatically memorised after 10 seconds.

M.36

NUDA 900 2012 - NUDA 900 R 2012

H105301

H10531

> 4”

> 4”

> 4”

1

ELECTRICAL SYSTEM


Setting units of measurementThe units of measurement must be set when the motorcycle is stationary and the key is set to ON.

- Press the “S” button (1) until the word “ODO” or “TEMP” appears on the dis-play.

- Press the “S” button for more than 4 seconds. The word “SET” appears on the display and the unit of measurement currently in use flashes.

- Press the “S” button once to change the unit of measurement. Once you have selected the unit of measurement, press the “S” button” for more than 4 seconds to confirm the set data and go onto the next scale.

The following units of measurement can be set:Km / mp = the display will show:- the speed in “km/h” or “mp/h” ; - the total distance covered in “km” or “mp”- the partial “TRIP” distance covered in “km” or “mp”.Temperature = °C / °FQuantity of fuel:L = (litres) - UG = US/GAL - IG = IM/GAL

- To quit the “SET” stage once you have made your last setting, press the “S” button for more than 4 seconds. If not, the program automatically quits after 10 seconds.

M.37

NUDA 900 2012 - NUDA 900 R 2012

H105321

H105331

H105341


ELECTRICAL SYSTEM

Setting parametersWith the dashboard on, press the “S” button (1) to display the various display functions:

ODO ; TRIP ; TEMP ; CON ; CLOCKThe “ODO”, “TEMP” and “CLOCK” functions are for display purposes only.

TRIP function:When this function is activated, press the “S” button for more than 4 seconds to reset and start a new partial count of the kilometres /miles subsequently travelled.

When this function is set after the fuel reserve light has come on, press the “S” button “S” (1) for more than 4 seconds to display fuel consumption (in litres or gallons depending on the unit of measurement you have selected) from when you go onto fuel reserve.

CON function:When this function is activated, press the “S” button for more than 4 seconds to reset and start a new count of the litres/ gallons consumed from when average consumption (L/100 km) has been reset.

Changing ECU mapping:The vehicle leaves the factory in “STANDARD” configuration, i.e, with maximum power.

Motorcycle performance can be changed from “STANDARD” to “RAIN” by press-ing the “M” button (1) on the dashboard.The map can be changed when the vehicle is moving (key turned to “ON”) or stationary.

Press the “M” button for more than 3 seconds: if the vehicle is moving, “MAP II” flashes intermittently on the display and the “RAIN” configuration is activated as soon as the accelerator is completely closed (“MAP II” permanently lit on the display) whereas if the vehicle is stationary, “MAP II” appears permanently lit after pressing the “M” button for more than 3 seconds.

To go from “RAIN” to “STANDARD” mapping, proceed in the same way.In “STANDARD” mode, there is no indication on the display.

When the vehicle is off (key turned to “OFF”) the current mapping is always maintained.

M.38

NUDA 900 2012 - NUDA 900 R 2012

H10536

2

4

3

H10535

1

H10537

4

H10538

5

ELECTRICAL SYSTEM


Control unit removal- Remove the relay support as described in the relevant paragraph.- Lift the control unit (1) removing it from the guides.

- Disconnect the connector (2) pressing with a screwdriver the tooth (3) and turning the locking element (4).

- Remove the rubber protection (5).

Refit a new control unit proceeding in the reverse order. To replace the part, use the diagnostic tool and follow the guided

procedure.

M.39

NUDA 900 2012 - NUDA 900 R 2012

H10539

2

1

1

H10540

3

4

H10541


ELECTRICAL SYSTEM

Ignition removal- Remove the relay support as described in the relevant paragraph.- Loosen the two screws (1) with the special wrench.- Lift the block (2) and disconnect the block connector (3) and the alarm system

connector (4).

Refit a new starter block proceeding in the reverse order. To replace the part, use the diagnostic tool and follow the guided

procedure.

Combined dashboard replacementFor the disassembly and reassembly procedures of the combined dashboard, see Chapter “E”.For the replacement of the part, use the diagnostic tool and follow the guided procedure.

M.40

NUDA 900 2012 - NUDA 900 R 2012

H10544

4

4

4

H10545

5

6

7

H10543

2

H10542

13

H10546

1 3

2

ELECTRICAL SYSTEM


Rear stop microswitch replacement- Loosen the three screws (1).- Remove the spring (2) and remove the cover (3).- Loosen the three screws (4), remove the upper part (5).- Disconnect connector (6) and remove the microswitch (7).

Clutch microswitch replacement- Remove the connector (1).- Loosen the screw (2) and replace the microswitch (3).

M.41

NUDA 900 2012 - NUDA 900 R 2012

H10514

1

H10547

2

H10548

3

H10549

2

2

H10550

2

1

4

H10551

3


ELECTRICAL SYSTEM

Front stop microswitch replacement- Remove the front fairing as described in the relevant paragraph.- Loosen the two screws (1) and remove the brake lever.- Lift the microswitch (2) to remove it.- Disconnect the connector (3).- Install a new microswitch inserting it with pressure in its seat.

Speed sensor replacement- Remove the fuel tank as described in the relevant paragraph.- Loosen the screw (1).- Remove the fastening from the harness (2).- Disconnect the connector (3).- Replace the sensor (4) and refit the harness as before.

M.42

NUDA 900 2012 - NUDA 900 R 2012

H10555

25

3

H10554

6H10553

4

H10552

1

7

H10556

21

ELECTRICAL SYSTEM


Stand rotative switch replacement- Remove the fuel tank as described in the relevant paragraph.- Loosen the nut (1) and remove the switch (2) from the stand.- Remove the fastening from the harness (3).- Disconnect the connector (4).- Replace the switch (2); during the reassembly, insert the switch tab (5) in the

hole (6) of the stand and the upper part of the switch in the centring pin (7).

12V plug replacement- Remove the fuel tank as described in the relevant paragraph.- Disconnect the connector (1).- Loosen the ring nut (2) and remove the 12V plug.

M.43

NUDA 900 2012 - NUDA 900 R 2012

H10557

1

H10558

2


ELECTRICAL SYSTEM

Water temperature sensor replacement- Remove the reservoir and bleed the cooling system as described in the relevant

paragraph.- Unhook the connector retainer (1) and remove the connector.- Loosen the sensor (2); replace and tighten it to torque (see Chapter F4).

M.44

NUDA 900 2012 - NUDA 900 R 2012

ELECTRICAL SYSTEM


Troubleshooting

Charging systemA battery that does not hold charge might be a symptom of:1) current draw (see paragraph "Battery");2) incorrect voltage (see paragraph "Regulated voltage");3) no continuity in generator (see paragraph "Checking generator stator wind-ings resistance");4) defective generator;5) voltage regulator malfunction (see paragraph "Voltage regulator/rectifier inspection")

- a battery overload indicates:1) faulty voltage regulator (see paragraph "Voltage regulator inspection");2) defective battery (see paragraph "Battery").

Starting systemIf the starter motor does not start, this might be a symptom of:1) faulty starter relay (see paragraph "Starter relay inspection");2) loose starter motor cable;3) faulty starter motor (see paragraph "Starter motor inspection");4) flat battery (see paragraph "Battery charger").

Electronic ignition systemA weak or missing spark might be a symptom of:1) incorrect connections in the electrical system;2) faulty spark plug or wrong heat rating or incorrect spark plug gap (see para-graph "Spark plug");3) defective starter coil/Stick-Coil (see paragraph "Coil/Stick-Coil winding resist-ance inspection").

M.45

NUDA 900 2012 - NUDA 900 R 2012

H10560

9

8

H10561

10

H105591

2

3

4 5 6

7

H10562

11

12


ELECTRICAL SYSTEM

Electrical connectors positioningIn the front part above the light, the following connectors to be found:1) Left-hand switch connectors.2) Headlight connector .3) Dashboard connector.4) R.H. turning indicator connector.5) Front stop microswitch connector .6) L.H. turning indicator connector.7) Right-hand switch connector.

On the right-hand side of the bike, the following connectors are to be found:8) TPS connector.9) Filter box stepper motor connector.

10) Electric fan connector.

11) Crankshaft position sensor connector.12) Gear position sensor connector.

M.46

NUDA 900 2012 - NUDA 900 R 2012

H10563

15

19

14

16

17

18

H10564

13

H10565

21

23

24

26

20

25

22

27

ELECTRICAL SYSTEM


In the area below the saddle and above the filter box, the following connectors are to be found:13) Air temperature sensor connector.14) Fuel pump connector.15) Diagnosis connector.16) Alarm system installation connector.17) Tail light connector.18) Number plate light and turning indicators connector.19) Fuses.

In the area below the reservoir and filter box, the following connectors are to be found:20) Relay connectors.21) Alarm system connector.22) Ignition connector.23) Control unit connector.24) Coil 1 connector.25) Coil 2 connector.26) Injector 1 connector.27) Injector 2 connector.

M.47

NUDA 900 2012 - NUDA 900 R 2012

H10567

30

31

32

34

35

33H10568

29

H10566

28


ELECTRICAL SYSTEM

In the central area behind the cylinder block, the following connectors are to be found:28) 12 volt plug connector.29) Water temperature sensor connector.30) Lambda sensor connector.31) Stand rotative switch connector.32) Speed sensor connector.33) Exhaust valve actuator connector.34) Solenoid starter connector.35) Voltage regulator connector.

M.48

NUDA 900 2012 - NUDA 900 R 2012

H10570

2

H10569

1

ELECTRICAL SYSTEM


ImportantBefore washing the motorcycle, it is necessary to duly protect the following parts from water:a) Rear opening of the muffler;b) Clutch and front brake levers, handgrips, handlebar switches;c) Air filter intake;d) Steering head, wheel bearings,In addition to these precautions, NEVER ALLOW HIGH-PRESSURE AIR OR WATER to get in contact with any ELECTRICAL PARTS, the FUEL INJEC-TION SYSTEM, and especially the electronic control unit (1) and the digital dashboard (2).

N.1

NUDA 900 2012 - NUDA 900 R 2012

N


ENGINE COOLING

Section

N.2

NUDA 900 2012 - NUDA 900 R 2012

ENGINE COOLING


Coolant level inspection................................................................................N.3Coolant replacement ....................................................................................N.3Cooling circuit ...............................................................................................N.6Engine cooling system overhaul ...................................................................N.7

N.3

NUDA 900 2012 - NUDA 900 R 2012

H10689

1

MAX

MIN

H10690

2

3

H10691

1


ENGINE COOLING

Coolant level checkWhen the engine is cold, check that the coolant level is between the two MIN and MAX marks on the expansion tank (1) on the right side of the vehicle.If topping up is necessary, do the following:- Remove the saddle and side panels, as described in the relevant para-

graphs.

Do not remove the radiator cap (2) since all the liquid in the expan-sion tank (1) will flow out.

- Remove the cap (3) and add the fluid needed to restore the level to the ex-pansion tank (1).

(for the type of liquid to use, see the paragraph “Technical data”).

Difficulties may arise in eliminating coolant from painted surfaces. If this occurs, wash off with water.

Coolant replacement- Put the motorbike in a vertical position.- Remove the saddle, the right-hand side as described in the relevant para-

graphs.- Put a 2 Lt capacity bucket under the engine.

- Loosen the screw (1) on the engine head and let the coolant drain.

N.4

NUDA 900 2012 - NUDA 900 R 2012

H10692

2

5

3

H10693

3

5

6

H10694

4

7

H10695

8

ENGINE COOLING


- Loosen the screw (2) of the lower pipe (3) that connects the radiator (4) to the exchanger (5).

- Remove the exchanger pipe (3) and let the coolant drain in the bucket; during the reassembly, replace the seal (6).

- Open the clamps (7) and remove the pipes (8) from the radiator allowing the coolant to drain fully from the radiator.

- Reassemble all previously removed components in the reverse order.

- Put the motorbike on the side stand.

N.5

NUDA 900 2012 - NUDA 900 R 2012

H10696

4

9

11

12

MAX

MIN

H10697

10


ENGINE COOLING

- Remove the radiator cap (9).

- Loosen the coolant bleed valve (10) on the water pump cover and at the same time continue to pour liquid in the radiator until it comes out of the hole of the bleed valve, then tighten again the bleed valve (10).



- Start the engine and leave it on until the radiator is warm, then turn off the engine and leave it to cool down for around 2-3 minutes.

- Turn the radiator cap (9) until the 1st safety notch and let the possible pres-sure discharge, then remove the cap.


- Restart the engine and repeat the procedures until the level of the radiator liquid reaches the maximum level.


- Remove the expansion tank (12) cap (11) and pour in liquid until the level is between the minimum and the maximum level.

- Refit the cap (11).

N.6

NUDA 900 2012 - NUDA 900 R 2012

H10882

5

1

2

3

4

6

7

8

9

ENGINE COOLING


Cooling circuit

The forced circulation cooling system uses a centrifugal pump (located to the right of the cylinder head) and two downdraft radiators.

1 Radiator cap2 Radiator3 Expansion tank4 Expansion tank cap5 Water pump6 Delivery coupling7 Intake coupling8 Cooling fan9 Reservoir / radiator connection pipe

N.7

NUDA 900 2012 - NUDA 900 R 2012

H10883

1

2

3

4

6

7

9


ENGINE COOLING

Servicing the engine cooling systemIf the coolant runs too hot, check the radiators. Any foreign matter trapped between the fins (such as leaves, bugs, mud, etc.) will obstruct air flow and must be removed carefully to avoid damage to radiator. Straighten any bent fins to ensure free flow of air. If the cooling mass is clogged or damaged, no more than 20% of its surface must be affected. If damage exceeds this limit, the radiator must be replaced. Periodically check the connecting hoses (see Section B, “Scheduled Maintenance Chart”); this will avoid coolant leakage and consequent engine seizure. If hoses show cracks, swelling or hardening due to sheaths desiccation, their replacement shall be advisable. Check the correct tightening of the clamps.

X.1

NUDA 900 2012 - NUDA 900 R 2012

X


TIGHTENING TORQUE FIGURES

Section

Tighten all nuts and screws to the specified torque using a torque wrench. If not tightened securely, a nut or a screw might become damaged or work itself loose, causing damage to motorcycle and injury to rider. An overtightened nut or screw might become damaged, its thread might strip, or the nut/screw might fail and work itself loose. Listed in the table are the tightening torque figures for the most important nuts and screws, which have determined in accord-ance with thread diameter, pitch and specific application. These figures are obtained after cleaning the threads with solvent.

X.2

NUDA 900 2012 - NUDA 900 R 2012



Tightening description Torque (Nm) Notes Safety

tighteningBattery to engine support 8.0Current plug to engine support 19.0Battery to chassis support 8.0Exhaust valve actuator to battery support 5.0Sprocket cover to engine 4.0Sprocket cover to chassis 4.0Rear brake pump to chassis 8.0Chassis protection to chassis 4.0Radiator support to L.H. chassis 5.0Radiator support to R.H. chassis 5.0Fan to radiator 3.0Radiator to support 5.0Relay support to filter box 3.0Expansion reservoir antifreeze to chassis 5.0Lower light support to headlight 5.0Dashboard support to headlight 2.0Headlight to steering head 5.0Front L.H. indicator to dashboard support 1.0Front R.H. indicator to dashboard support 1.0Front mudguard to fork 5.0Chain protection to swinging arm 8.0Saddle support bracket to small chassis 5.0Number plate holder to small chassis 5.0Tools support bowl to small chassis 2.0Tail to small chassis 2.0Front mudguard tail fastening 2.0Headlight cover fastening 2.0Side to L.H. tail 2.0Side to upper L.H. tail 2.0Side to L.H. reservoir support 2.0Side to L.H. chassis 2.0Side to L.H. filter box 3.0Side to R.H. tail 2.0Side to R.H. upper tail 2.0Side to R.H. reservoir support 2.0Side to R.H. chassis 2.0Side to R.H. filter box 3.0Central airbox cover 2.0Airbox cover to chassis 2.0Airbox cover to reservoir cap ring nut 2.0Airbox cover to reservoir 2.0Fuel pump cover 35.0Reservoir cap to reservoir 3.0

X.3

NUDA 900 2012 - NUDA 900 R 2012




tighteningReservoir support to small chassis 5.0Number plate light to number plate holder 3.0Number plate holder cover 0.5Passenger handle to number plate holder 6.0Internal side 2.0Internal side 2.0Exhaust valve actuator cover 3.0

Ground cable starter to engine 8.0Positive cable to starter motor 6.0Ground cable to engine head 8.0Horn to chassis 8.0Speed sensor to support 8.0L.H. switch to handlebar 2.0R.H. switch to handlebar 2.0L.H. indicator to number plate holder 2.0R.H. indicator to number plate holder 2.0Tail light to number plate holder 5.0Current plug to support 3.5

Chain slider to chassis 4.0Steering nut 80.0 SUpper fork locking 19.0 SHeadlight pins to bottom yoke 8.0Rear brake fluid reservoir to chassis 2.0Rear brake lever to chassis 38.0 SShock absorber to chassis 75.0 SShock absorber to swinging arm 45.0 SKey block to chassis 19.0Steering lock to R.H. chassis 1.5Steering lock to L.H. chassis 1.5Small chassis to chassis 38.0 PRE-IMPREGNATED SFuel reservoir to chassis 8.0Reservoir support to reservoir 5.0Side stand support to chassis 38.0 PRE-IMPREGNATED SSide stand to support 38.0 PRE-IMPREGNATED SPin for side stand springs 19.0 Loctite 243Side stand foot 19.0 Loctite 243Pass. footrest support to L.H. small chassis 19.0 SPass. footrest support to R.H. small chassis 19.0 SFront wheel pin 50.0 SFront wheel pin locking 8.0Front calliper to fork 38.0 S

X.4

NUDA 900 2012 - NUDA 900 R 2012




tighteningFront brake eyelet to bottom yoke 8.0Side stand switch 5.0Rear brake hose ring to swinging arm 5.0Chassis slider to swinging arm 5.0Lower handlebar clamps to steering head 38.0 SUpper clamps to lower clamps 19.0 SBrake master cylinder to handlebar 5.0Front brake disc fastening * 27.0 PRE-IMPREGNATED SRear brake disc fastening * 27.0 PRE-IMPREGNATED SOil reservoir brackets to front master cylinder 8.0Brake oil reservoir to bracket 4.0Brake pipe to front master cylinder 20.0 SBASE version; brake pipe to front calliper 16.6 SBASE version; brake pipe to front calliper 16.6 SBrake bleed valve to front calliper 8.0R version, brake pipe to front calliper 20.0 SR version, brake pipe to front calliper 20.0 SBrake pipe to rear pipe 10.0 SBrake pipe to rear calliper 20.0 S

Sprocket to engine 50.0 Loctite 243 SExhaust pipe to engine head 14.0Exhaust pipe to chassis 19.0Lambda sensor 45.0Clutch cable locking 2.0Throttle cable locking 2.5Filter box to front chassis 8.0Filter box to rear chassis 3.0Gear shift pedal to engine 8.0Silencer to support 19.0Silencer clamp 19.0Silencer protection fastening 4.0Clutch lever to handlebar 5.0Handlebar throttle control 3.0

* Tighten in a cross pattern.

NOTE: THE PRE-IMPREGNATED SCREWS MUST BE REPLACED AT EVERY DISASSEMBLY.

X.5

NUDA 900 2012 - NUDA 900 R 2012



Sequences / further instructions Torque (Nm) Notes Safety

tighteningEngine to chassis

Engine to chassis, front L.H. 66.0 step 1 SEngine to chassis, central L.H. 38.0 step 2 SEngine to chassis, lower L.H. 38.0 step 3 SSwinging arm shaft 100.0 step 4 SEngine to chassis, front R.H. 66.0 step 5 SEngine to chassis, central R.H. 38.0 step 6 SEngine to chassis, lower R.H. 38.0 step 7 S

Steering ring nutFirst tightening 15.0 step 1 SLoosen 60° step 2 SFinal Tightening 10.0 step 3 S

Sprocket to sprocket holderPre-tightening sprocket to support * 10.0 step 1Final tightening sprocket to support * 90° step 2 S

* Tighten in a cross pattern.

1Nm = 0,1 Kgm = 0,73756 ft/lb

X.6

NUDA 900 2012 - NUDA 900 R 2012



NOTE: Unless otherwise specified, standard torque values for the different thread sizes are as follows (+/- 5%)

Steel screws on plastic, with metal spacers M4 2 Nm 0.2 Kgm 1.45 ft/lb

Steel screws on brass, copper, aluminium M4 2 Nm 0.2 Kgm 1.45 ft/lb

Steel screws on iron, steel M4 3 Nm 0.3 Kgm 2.2 ft/lb

Steel screws on plastic, with metal spacers M5 4 Nm 0.4 Kgm 3 ft/lb

Steel screws on brass, copper, aluminium M5 4 Nm 0.4 Kgm 3 ft/lb


Steel screws on plastic, with metal spacers M6 6.5 Nm 0.65 Kgm 4.8 ft/lb

Steel screws on brass, copper, aluminium M6 6.5 Nm 0.65 Kgm 4.8 ft/lb

Steel screws on iron, steel M6 10.5 Nm 1 Kgm 7.7 ft/lb

Steel screws on brass, copper, aluminium M8 16 Nm 1.6 Kgm 11.8 ft/lb



Steel screws on iron, steel M12 100 Nm 10 Kgm 73.8 ft/lb

Steel screws on iron, steel M14 145 Nm 14.5 Kgm 107 ft/lb

1 Nm = 0,1 Kgm = 0,73756 ft/lb

Y.1

NUDA 900 2012 - NUDA 900 R 2012

Y


CHASSIS AND WHEELS

Section

Y.2

NUDA 900 2012 - NUDA 900 R 2012

CHASSIS AND WHEELS


Chassis ......................................................................................................... Y.3Lubrication points (lubricant) ........................................................................ Y.3Front wheel ................................................................................................... Y.5Front wheel disassembly ............................................................................. Y.6Front wheel reassembly .............................................................................. Y.7Rear wheel ................................................................................................... Y.9Rear wheel disassembly............................................................................. Y.10Wheel axle warpage ................................................................................... Y.11Pin misalignment on 100 mm ..................................................................... Y.11Wheel rims deformation.............................................................................. Y.11Rear sprocket, secondary transmission sprocket and chain ...................... Y.12Sprocket wear inspection ........................................................................... Y.12

Y.3

NUDA 900 2012 - NUDA 900 R 2012

H10884

1

1


CHASSIS AND WHEELS

ChassisThe chassis is a tubular steel trellis type with stainless steel removable rear small chassis.

In case of violent shocks or accidents, if you think that the chassis might be bent or damaged, proceed with an im-mediate inspection and, if necessary, replace it.

Lubrication points (lubricant)

1 Steering bearings (grease)

Y.4

NUDA 900 2012 - NUDA 900 R 2012

H10885

A A

A

A

A

A

H10886

C

B

B

B

C

C

C

D

CHASSIS AND WHEELS


Y.5

NUDA 900 2012 - NUDA 900 R 2012

H10887

11

12

1314

15

6

17

14

3

8 18


CHASSIS AND WHEELS

Check the assemblies shown in the figurefor cracks or damage.If any are found, replace the part.A ENGINE MOUNTING SCREWSB REAR CHASSIS MOUNTING SCREWSC FOOTREST-PINS-SPRINGSD PASSENGER FOOTREST MOUNTING SCREWS

Front wheel

1) Tyre2) Rim3) Bearings4) Sealing rings5) Inner spacer6) Outer spacer7) Wheel axle8) Brake discs

Y.6

NUDA 900 2012 - NUDA 900 R 2012

H10888

1

H10889

2

H108903

H10891

4

3

CHASSIS AND WHEELS


Removing the front wheel Set a stand or a block under the engine and see that the front wheel is lifted from the ground.

- Loosen the screws (1) to remove the callipers.

- Loosen the two screws (2) on the right-hand fork leg that lock the pin.

- From the right-hand side, loosen the pin (3), extract it and remove the wheel (4).

Y.7

NUDA 900 2012 - NUDA 900 R 2012

H10892

1

3

H10893

2

H108903


CHASSIS AND WHEELS

Refitting the front wheel- Refit the wheel (1) in the fork making sure that you position the spacer (2) on

the left-hand side of the wheel.

- Insert the pin (3) and tighten it to torque.

Y.8

NUDA 900 2012 - NUDA 900 R 2012

H10894

4

H10895

65

CHASSIS AND WHEELS


- Tighten the screws (4) to lock the pin (3) on the leg of the right-hand fork.

- Reinstall on both sides the callipers (5) and tighten the screws (6) to torque.

Note: During the reassembly of the callipers, first of all insert the retain-ing screws manually then, before tightening them to the specified torque, keep the lever of the front brake pulled, for example with an elastic. Only at this point, tighten the retaining screws of the callipers to the specified torque.


After reassembly, pull the brake control lever until the pads are against the brake disc.

Y.9

NUDA 900 2012 - NUDA 900 R 2012

H10896

1

2

34

56

7 8

94

1011

12

13

14

45

6


CHASSIS AND WHEELS

Rear wheel

1) Tyre2) Rim3) Inner spacer4) Bearings5) Elastic rings6) Sealing rings7) Outer spacer8) Phonic wheel9) Outer spacer10) Cush drive dampers11) Sprocket holder hub12) Spacer13) Sprocket14) Brake Disc

Y.10

NUDA 900 2012 - NUDA 900 R 2012

H10897

1

2

H10898

3

H10899

4

H10900

5

CHASSIS AND WHEELS


Removing the rear wheelSet a stand or a block under the engine and see that the rear wheel is lifted from the ground.

Unscrew the nut (1) of the wheel axle (3) and extract it. It is not necessary to loosen the chain tensioners (2); in this way, the chain tension will remain unchanged after reassembly. Remove the chain (4) and remove the full wheel paying atten-tion to the spacers on the sides of the hub. For reassembly follow the removal procedure in the reverse order by inserting the brake disc in the calliper.

Check the cush drive dampers for wear (5); if only one of the ap-pears to be damaged, all of them must be replaced.

Do not operate the rear brake pedal when the wheel has been re-moved; this causes the calliper pistons to move outwards.

After removal, lay down the wheel with brake disc on top.

After reassembly, depress the brake pedal until the pads are against the brake disc.

Y.11

NUDA 900 2012 - NUDA 900 R 2012

H10901

H10902

H10903

1

21

1

1

1

12

16

1

C

MAX

MIN


CHASSIS AND WHEELS

Wheel axle warpageUse a feeler gauge to check the pint out-of-round; if the value of the warpage exceeds the max allowed limit, replace it.

Axle runout over 100 mm

Wheel axle Standard Max. limit Wheel axle less than 0.1 mm 0.2 mm (0.079 in.) less than 0.039 in.

PINFRONT

Wheel rim warpageThe table below reports the allowed limits for wheel rim warpage. An excessive side runout and out-of-round are generally caused by worn out bearings. In these cases, replace the bearings and the sealing rings. If this does not solve the problem, change the wheel rim or the wheel.

Standard Max. limit

Side runout less than 0.5 mm (0.02 in.) 2 mm (0.079 in.) Out-of-round less than 0.8 mm (0.03 in.)

PINREAR

Y.12

NUDA 900 2012 - NUDA 900 R 2012

H10904

1

2

H10905

1

CHASSIS AND WHEELS


Rear chain sprocket, secondary drive sprocket and chainThe figure at the side shows the profiles of a normally worn and an exceedingly worn sprocket.

1 Normal wear

2 Exceeding wear

If the sprocket is exceedingly worn, replace it after loosening the six nuts (1) that retain it to the cush drive damper.

Chain and sprockets must always be replaced as a set.

Checking sprocket wear

Check the transmission sprocket for damage or wear. When worn down like the sprocket shown in the figure, it must be replaced.

Wheel misalignment causes abnormal wear, making the motorcycle unsafe to ride.

nuda 900 2012 nuda 900 r 2012

Documents